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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of co-pending application Ser. No. 07/483,612, filed Feb. 22, 1990, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to benzoxazolinones. More specifically, this invention relates to certain benzoxazolinone compounds substituted not only at the 6-position with an amino side chain but also at the 4-, 5- or 7-position of the benzo-ring. Such compounds inhibit the action of lipoxygenase and/or cyclooxygenase enzymes and are useful as inhibitors of those enzymes, per se. The compounds of this invention are also useful in the treatment of a variety of allergic and inflammatory conditions in mammals. This invention also relates to pharmaceutical compositions comprising such benzoxazolinone compounds.
European patent application, published Dec. 16, 1987 under No. 249407, discloses benzoxalone compounds having an alkylamino group at the 6-position, which are lipoxygenase and/or cyclooxygenase inhibitors.
SUMMARY OF THE INVENTION
This invention provides novel benzoxazolinone compounds of the formula: ##STR1## or a pharmaceutically-acceptable acid addition salt thereof,
wherein Alk is a C n straight or branched chain divalent alkyl group; n is 0, 1, 2, 3, 4 or 5;
R 1 is (C 1 -C 3 )alkyl or (C 1 -C 3 )alkoxy, (C 1 -C 3 )alkylthio, hydrogen, halo, phenoxy, phenylthio or trifluoromethyl; and
R is selected from the group consisting of: ##STR2## wherein R 2 and R 3 are each, independently, H, (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy, (C 1 -C 4 )alkylthio, or halo, X is methylene which is unsubstituted or substituted with one methyl group, nitrogen which is unsubstituted or substituted with a protecting group, oxygen, sulfur, sulfoxide or sulfone, and the dotted line between the 2- and 4- positions represents an optional bond between positions 2 and 3 or positions 3 and 4; ##STR3## wherein A and B are each, independently, O or S; ##STR4## wherein R 4 and R 5 are each, independently, H or (C 1 -C 4 )alkyl, p is 0, 1 or 2 and t is 0, 1 or 2 provided that the sum of p plus t equals 1 or 2; and the wavy line indicates that the moiety containing such wavy line can be endo- or exo-7-oxabicyclo[2,2,1]heptan-1-yl; and
(e) CH 3 --(CH 2 ) m --Y--
wherein m is an integer from 1 to 3 and Y is oxygen, sulfur, sulfoxide or sulfone.
The term "halo" as used herein means fluoro, chloro, bromo or iodo. The term "nitrogen protecting group" as used herein means t-butoxycarbonyl, benzoyloxycarbonyl, acetyl or formyl.
A preferred group of compounds are those wherein n is 0 or 1, R 1 is halo, R is a member selected from Group (a). Especially preferred are those wherein R 1 is 5-fluoro and X is oxygen.
A second preferred group of compounds are those wherein n is 1, R 1 is halo and R is a member selected from Group (c). Especially preferred are those wherein R 1 is 5-fluoro.
A third preferred group of compounds are those wherein n is 1, R 1 is (C 1 -C 3 )alkyl, and R is a member selected from Group (a). Especially preferred are those wherein R 1 is 5-ethyl and X is oxygen.
A fourth preferred group of compounds are those wherein n is 1 and R is a member selected from Group (d). Especially preferred are those wherein R 1 is 5-fluoro.
A fifth preferred group of compounds are those wherein R 1 is halo and R is a member selected from Group (e). Especially preferred are those wherein R 1 is 5-fluoro, m is 1 and Y is oxygen.
A sixth preferred group of compounds are those wherein R 1 is (C 1 -C 3 )alkoxy and R is a member selected from Group (a). Especially preferred are those wherein R 1 is methoxy, n is 1 and X is oxygen.
The compounds of formula (I) may contain an asymmetric center, and therefore may exist as a pair of enantiomers. This invention is to be considered as embracing each pure enantiomer thereof, the racemates thereof and a mixture of the enantiomers thereof, partially or completely optically resolved.
The pharmaceutically-acceptable acid addition salts of the compounds of the formula (I) are those formed from acids which form non-toxic acid addition salts, for example, the hydrochloride, hydrobromide, sulfate or bisulfate, phosphate or acid phosphate, acetate, citrate, fumarate, gluconate, lactate, maleate, succinate, tartrate, methanesulfonate, benzene sulfonate, toluenesulfonate, and formate salts.
This invention includes pharmaceutical compositions for treatment of allergic inflammatory conditions in a mammal which comprise a pharmaceutically-acceptable carrier or diluent and a compound of formula (I) or a pharmaceutically-acceptable acid addition salt thereof. This invention also includes a method for treating an allergic or inflammatory condition in a mammal, especially man, which comprises administering to said mammal an antiallergy or antiinflammatory effective amount of a compound of formula (I) or a pharmaceutically-acceptable acid addition salt thereof.
Also embraced by the present invention is a method of inhibiting the action of the lipoxygenase enzyme as well as the action of the cyclooxygenase enzyme in a mammal in need thereof, which comprises administering to such mammal a lipoxygenase enzyme and/or cyclooxygenase enzyme inhibiting amount of a compound of formula (I) or a pharmaceutically-acceptable acid addition salt thereof. This invention also includes pharmaceutical compositions for inhibiting the action of lipoxygenase enzyme and/or cyclooxygenase enzyme in a mammal which comprise a pharmaceutically-acceptable carrier and a compound of formula (I) or a pharmaceutically-acceptable acid addition salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
The novel compounds of formula (I) may be prepared by the following reaction scheme: ##STR5##
In the above formulae, Alk; R; and R 1 are as previously defined and n is 0, 1, 2, 3 or 4. In the first step, approximately equimolar amounts of the reactants, amine (II) and aldehyde (III) are combined in a suitable organic solvent. While the reaction is preferably conducted at ambient temperature, higher temperatures, for example, reflux, can be used without any significant disadvantages. Suitable organic solvents include (C 1 -C 4 )alkanol (e.g., methanol or ethanol), benzene, toluene and tetrahydrofuran. It may be advantageous to use a dehydrating agent. Molecular sieves are a preferred dehydrating agent. Optionally, a small amount of lower alkanoic acid such as acetic acid is added to catalyze the reaction. The reaction is essentially complete within 24 hours. The product of the formula (IV) can be isolated and purified by conventional procedures, e.g. recrystallization or chromatography, when the resulting imine is conjugated with an unsaturated group. It is, however, more convenient not to isolate this product but to subject it (i.e., in situ) to reaction conditions of the second step.
The second step of the reaction involves reduction of the C═N double bond by reaction with an appropriate hydrogen source. While the reduction may be carried out by employing a wide variety of reducing agents which are known to reduce a carbon-nitrogen double bond, the preferred method of this invention employs a metal hydride reagent or catalytic hydrogenation reaction. The hydride reagents suitably employed in this reaction include sodium borohydride, sodium cyanoborohydride and lithium cyanoborohydride. Typically, the reduction is carried out at ambient temperature, with an excess of the hydride reagent in (C 1 -C 4 )alkanol such as methanol or ethanol. A catalytic hydrogenation reaction employs a catalytic amount of a noble metal catalyst such as Pd/C or PtO 2 under hydrogen atmosphere. When the reduction is substantially complete, the desired product of formula (I) is isolated by standard methods. Purification can be achieved by conventional means, such as recrystallization or chromatography.
Certain compounds of formula (I) wherein n is 0 and R is a member selected from Group (a) are also obtained substantially in a similar manner to the process described above. However, for this group of compounds the process requires a ketone instead of aldehyde (III). Preferably, the required ketone can be any one of the following: ##STR6## where X is methylene which is unsubstituted or substituted with one methyl group, nitrogen which is unsubstituted or substituted with a protecting group, oxygen or sulfur and R 2 and R 3 are as defined above. For example, coupling of the compound (II) and the ketone (V) yields the imine of formula (VIII). ##STR7## The latter compound is readily reduced to the desired compound (I). Convenient conditions for the above two-step conversion are not significantly different from those employed with the synthesis of compounds (I) where n is other than 0.
Compounds of formula (I) wherein R is a member of Group (a) wherein X is sulfoxide or sulfone; or R is a member of Group (e) wherein Y is sulfoxide or sulfone are prepared by oxidation of the corresponding compounds wherein X and Y are sulfur. The unoxidized compounds are prepared as described above. Suitable oxidation conditions include, but are not limited to, reaction of such compounds with alumina supported sodium metaperiodate in a suitable solvent such as (C 1 -C 3 )alkanol and/or tetrahydrofuran.
The olefinic products of formula (I), i.e., those having an optional double bond between the 2- and 4-positions of the R radical are themselves active inhibitors of LO/CO enzymes and also serve as intermediates for preparation of the corresponding reduced compounds of the formula: ##STR8## A particularly preferred method for such reduction comprises hydrogenating a compound of formula (I) to be reduced under hydrogen in the presence of a noble metal catalyst in a suitable solvent. Suitable solvents for this hydrogenation are, for example, diethyl ether, etrahydrofuran, dioxane, ethyl acetate and (C 1 -C 3 )alkanol such as methanol or ethanol. The noble metal catalysts used are known in the art, for example, nickel, palladium, platinum and rhodium. Particularly preferred agents are platinum oxide and palladium on carbon. A platinum catalyst is sometimes more preferred because it is not readily poisoned by sulfur. This hydrogenation requires low hydrogen pressure (1 to 4 atm) and runs at ambient temperature. When the hydrogenation is complete (from about 2 hours to 24 hours), the catalyst is removed by filtration and the product of formula (IX) is then isolated and purified, if desired, by a conventional method.
6-Aminobenzoxazolin-2-ones (II) are prepared by a variety of methods known in the art and illustrated in the Preparations hereinbelow. The aldehydes or ketones required for the above syntheses are available commercially, or by preparation according to literature methods.
The pharmaceutically-acceptable salts of the novel compounds of the present invention are readily prepared by contacting said compounds with a stoichiometric amount of an appropriate mineral or organic acid in either aqueous solution of in a suitable organic solvent. The salt may then be obtained by precipitation or by evaporation of the solvent.
The compounds of this invention inhibit the activity of the lipoxygenase and/or cyclooxygenase enzymes. This inhibition has been demonstrated by an assay using rat peritoneal cavity resident cells which determines the effect of said compounds on the metabolism of arachidonic acid.
In this test some preferred compounds indicate low IC50 values, in the range of 0.5μ to 30 μM, with respect to both lipoxygenase/cyclooxygenase inhibitions.
The ability of the compounds of the present invention to inhibit lipoxygenase and/or cyclooxygenase enzymes make them useful for controlling the symptoms induced by the endogenous metabolites arising from arachidonic acid in a mammalian subject. The compounds are therefore valuable in the prevention and treatment of such disease states in which the accumulation of arachidonic acid metabolites are the causative factor, e.g., allergic bronchial asthma, skin disorders, rheumatoid arthritis, osteoarthritis and thrombosis.
The activity of the compounds of this invention can also be demonstrated in the standard carrageenin-induced rat foot edema test (C. A. Winter et al., Proc. Soc. Exp. Biol. III, p 544, 1962).
Thus, the compounds of formula (I) and their pharmaceutically-acceptable salts are of particular use in the treatment or alleviation of allergic or inflammatory conditions in a human subject as well in the inhibition of the cyclooxygenase and lipoxygenase enzymes.
For treatment of the various conditions described above, the compounds of formula (I) and their pharmaceutically-acceptable salts can be administered to a human subject either alone, or, preferably, in combination with pharmaceutically-acceptable carriers or diluents in a pharmaceutical composition, according to standard pharmaceutical practice. A compound can be administered by a variety of conventional routes of administration including orally, parenterally and by inhalation. When the compounds are administered orally, the dose range will be from about 0.1 to 20 mg/kg body weight of the subject to be treated per day, preferably from about 0.1 to 1.0 mg/kg per day in single or divided doses. If parenteral administration is desired, then an effective dose will be from 0.1 to 1.0 mg/kg body weight of the subject to be treated per day. In some instances it may be necessary to use dosages outside these limits, since the dosage will necessarily vary according to the age, weight and response of the individual patient as well as the severity of the patient's symptoms and the potency of the particular compound being administered.
For oral administration, the compounds of formula (I) and their pharmaceutically-acceptable salts can be administered, for example, in the form of tablets, powders, lozenges, syrups or capsules, or as an aqueous solution or suspension. In the case of tablets for oral use, carriers which are commonly used include lactose and corn starch. Further, lubricating agents, such as magnesium stearate, are commonly added. In the case of capsules, useful diluents are lactose and dried corn starch. When aqueous suspensions are required for oral use, the active ingredient is combined with emulsifying and suspending agents. If desired, certain sweetening and/or flavoring agents can be added. For intramuscular, intraperitoneal, subcutaneous and intravenous use, sterile solutions of the active ingredient are usually prepared, and the pH of the solutions should be suitably adjusted and buffered. For intravenous use, the total concentration of solute should be controlled to make the preparation isotonic.
The present invention is illustrated by the following examples. However, it should be understood that the invention is not limited to the specific details of these examples Proton nuclear magnetic resonance spectra (NMR) were measured at 270 MHz unless otherwise indicated for solutions in perdeuterodimethyl sulfoxide (DMSO-d 6 ) and peak positions are expressed in parts per million (ppm) downfield from tetramethylsilane. The peak shapes are denoted as follows: s, singlet; d, doublet; t, triplet; m, multiplet; br, broad.
EXAMPLE 1
5-Fluoro-6-[(5,6-Dihydro-2H-pyran-3-yl)methylamino]benzoxazolin-2-one
To a solution of 6-amino-5-fluoro-benzoxazolin-2-one (0.97 g, 5.7 mmole) and 3-formyl-5,6-dihydro-2H-pyran (0.71 g, 6.3 mmole) in ethanol (40 ml) were added molecular sieves (4A, 1 g). The mixture was heated under reflux for 3 hours. Upon cooling, the reaction mixture was filtered and the filtrate was concentrated to yield a solid product, which was washed with ethanol. This product was dissolved in methanol (200 ml) and then sodium borohydride was added in portions at room temperature. Stirring was continued for hours. The reaction mixture was concentrated and water was added. The organic material was extracted with ethyl acetate. The combined extracts were washed with brine, dried over magnesium sulfate, and concentrated. The resulting residue was recrystallized from methanol to afford 420 mg of the title product (28%): m.p. 175°-176° C.
IR (KBr): 1790, 1520, 1100, 960 cm -1 .
NMR: 2.03 (br, 2H), 3.61 (m, 4H), 3.97 (br, 2H), 5.53 (br, 1H), 5.74 (br, 1H), 6.68 (d, 1H), 6.90 (d, 1H), 11.23 (s, 1H).
__________________________________________________________________________EXAMPLES 2-7In a like manner, employing the appropriate aldehydes (III) in theprocedure ofExample 1 afforded the corresponding compounds of formula (I). ##STR9##Example IR(cm.sup.-1)No. n R R.sub.1 m.p. (°C.) (Nujol) NMR__________________________________________________________________________2 1 ##STR10## F 191-192 1770, 1520 2.22(br, 2H), 2.60(t, 2H), 3.02(br, 2H), 3.65(d, 2H), 5.61(br, 1H), 5.73(s, 1H), 6.65(d, 1H), 6.90(d, 1H), 11.22(br, 1H)3 1 ##STR11## F 224-225 (dec.) 1780, 1650 1505 2.22(t, 2H), 2.74(t, 2H), 3.86(d, 2H), 5.77(br, 1H), 6.37(s, 1H), 6.68(d, 1H), 6.92(d, 1H), 6.95-7.10(m, 4H), 11.2(br, 1H)4 1 ##STR12## CH.sub.3 O5 1 ##STR13## CH.sub.3 CH.sub.2 (CDCl.sub.3)2.04-2.12(2H, m)3.72-3.76 (2H, m), 4.08-4.14(2H, m), 5.79(1H, 2), 6.39(1H, s), 6.69(1H, s)6 1 ##STR14## F 180-182 1756 (CDCl.sub.3)1.25(d, J=6.3Hz, 3H), 1.34(d, J=6.8Hz, 3H), 2.00(br.s, 2H), 3.57-3.73 (m, 3H), 3.90(br.s, 1H), 4.30(br.s, 1H), 5.79(br.s, 1H), 6.60(d, J=7.1Hz, 1H), 6.80 (d, J=10.3Hz, 1H), 8.72(br.s,__________________________________________________________________________ 1H)
EXAMPLE 8
5-Fluoro-6-[(tetrahydro-4H-pyran-3-yl)propylamino]benzoxazolin-2-one
To a solution of 6-amino-5-fluoro-benzoxazolin-2-one (2.1 g, 12.5 mmole) in methanol (80 ml) were added 3-(tetrahydro-2H-pyran-3-yl) propanal (1.95 g, 13.7 mmole) and acetic acid (1 ml) at room temperature, and then the mixture was stirred for 1 hour. Sodium cyanoborohydride (0.867 g, 13.7 mmole) was combined and stirring continued for 17 hours at room temperature. The reaction mixture was concentrated in vacuo, and the residue was treated with aqueous ammonium chloride solution. The organic substance was extracted with ethyl acetate/tetrahydrofuran. The extracts were washed with brine, dried over magnesium sulfate, and concentrated to afford crude product. This crude product was recrystallized from methanol to give 1.40 g of the title compound: m.p. 144°-145° C.
IR (KBr): 1770, 1090 cm -1 .
NMR: 1.00-1.30 (m, 3H), 1.38-1.63 (m, 5H), 1.75-1.85 (m, 1H), 2.91-3.03 (m, 3H), 3.20-3.28 (m, 1H), 3.73 (br.d, 2H), 5.13 (br, 1H), 6.73 (d, 1H), 6.89 (d, 1H), 11.21 (br, 1H).
EXAMPLES 9-33
In like manner, employing the appropriate aldehydes (III) or ketones (V)-(VII) in the procedure of Example 8 afforded the corresponding compounds of formula (I). ##STR15## wherein Alk is (CH 2 ) n
__________________________________________________________________________Example IR(cm.sup.-1)No. n R R.sub.1 m.p. (°C.) (Nujol) NMR__________________________________________________________________________ 9 0 ##STR16## F 200-202 3430, 1780 1760 1.11-1.40(m, 5H), 1.58-1.72(m, 3H), 3.16-3.18(m, 1H), 4.71(d, 1H, J=7Hz), 6.89(d, 1H, J=10Hz), 11.21(br.s, 1H)10 1 ##STR17## CH.sub.3CH.sub.2 143-144 3480, 1960 1905, 1850 1760 0.89-0.98(m, 1905, 2H), 1.10-1.21(m, 5H), 2.43-2.50(m, 5H), 2.86-2.90(m, 2H), 3.30-3.32(m, 2H), 4.69(m, 1H), 6.47(s, 1H), 6.69(s, 1H), 10.98(br.s, 1H)11 1 ##STR18## F 170(dec) 3460, 3220 1775, 1750 0.90(d, 4H), 1.25-1.82(m, 5H), 2.18(s, 3H), 2.95(d, 1H, J=6Hz), 6.60(d, 1H, J=6Hz), 6.77(d, 1H), 8.06(br.s, 1H)12 0 ##STR19## F 220-221 3340, 1770 1.44(dd, 2H), 1.82(d, 2H), 3.28-3.52(m, 3H), 3.85(d, 2H), 4.93(dd, 1H), 6.88-6.92(m, 2H), 12.62(br.s, 1H)13 0 ##STR20## F 204-205 1760, 1730 1660 1.42-1.70(m, 3H), 1.93(m, 1H), 3.18(dd, 1H, J=8.6, 11Hz), 3.68-3.82(m, 2H), 4.81(m, 1H), 6.88(d, 1H, J=7.3Hz), 6.90(d, 1H, J=11.0Hz)14 1 ##STR21## F 198-199 3450, 1780 1.17(d, 2H), 1.64(d, 2H), 1.82(m, 1H), 2.94(t, 2H), 3.25(d, 2H), 3.84(d, 2H), 5.25(m, 1H), 6.76(d, 1H), 6.88(d, 1H)15 2 ##STR22## F 191-192 1780, 1650 1.17(m, 2H), 1.45-1.62(m, 5H), 3.05(m, 2H), 3.82(dd, 2H, J=3.3, 10.6Hz), 5.12 (m, 1H), 6.74(d, 1H, J=7.3Hz), 6.89(d, 1H, J=11.0Hz)16 1 ##STR23## F 110-112 3500, 1790 1.70-2.22(m, 4H), 3.19-3.33(m, 2H), 4.06(m, 1H), 4.23(m, 1H), 4.74(m, 1H), 6.40(d, 1H), 6.66(d, 1H), 6.79(d, 1H), 8.19(br.s, 1H)17 1 ##STR24## F 225(dec) 1760, 1500 3.30-3.40(m, 2H), 4.01(dd, 1H), 4.33-4.40(m, 2H), 5.45-5.46(m, 1H), 6.80-6.95(m, 6H)18 2 CH.sub.3CH.sub.2O F 152-153 3480, 1790 1.11(t, 3H, J=7.0Hz), 3.21(m, 2H), 3.45(q, 1770, 1660 2H, J=7.0Hz), 3.52(t, 2H, J=6Hz), 5.03(m, 1H), 6.83(d, 1H, J=7.7Hz), 6.91(d, 1H, J=11Hz), 11.25(br.s, 1H)19 3 CH.sub.3CH.sub.2O F 127-128 3480, 1790 1.11(t, 3H, J=7.0Hz), 1.77(m, 2H), 3.05-3.13 1770, 1660 (m, 2H), 3.46-3.46(m, 4H), 5.21(br.s, 1H), 6.74(d, 1H, J=7Hz), 6.90(d, 1H, J=11Hz), 11.3(br.s, 1H)20 4 CH.sub.3CH.sub.2O F 66-67 3480, 1790 1.22(t, 3H, J=7.1Hz), 1.72(m, 4H), 3.14(m, 1770, 1660 2H), 3.45-3.54(m, 4H), 3.91(br.s, 1H), 6.62 (d, 1H, J=7Hz), 6.78(d, 1H, J=10Hz), 8.72 (br.s, 1H)21 5 CH.sub.3CH.sub.2 O F 75-76 3480, 1790 1.21(t, 3H, J=7.0Hz), 1.43-1.74(m, 6H), 3.11 1770, 1660 (t, 2H, J=7.0Hz), 3.42-3.52(m, 4H), 3.79(br.s, 1H), 6.61(d, 1H, J=7.1Hz), 6.79(d, 1H, J=10Hz), 8.95(br.s, 1H)22 1 ##STR25## F 184-186 3450, 3380 1764, 1732 1.17-1.27(m, 1H), 1.35-1.62(m, 5H), 2.02-2.06 (m, 1H), 2.68-2.77(m, 1H), 2.84-2.96(m, 1H), 4.34(d, 1H, J=4.8Hz), 4.48(dd, 1H, J=4.4, 4.8Hz), 5.40(br.s, 1H), 6.72(d, 1H, J=7.3Hz), 6.89(d, 1H, J=10.6Hz), 11.21(s, 1H)23 1 ##STR26## F 192-194 3450, 1774 1650, 1628 1132, 1.00(dd, 1H, J=5.1, 11.7Hz), 1.36-1.57(m, 3H), 1.73-1.89(m, 2H), 2.29-2.40(m, 1H), 2.98-3.06 m, 2H), 4.41-4.49(m, 2H), 5.12(br.s, 1H), 6.82 (d, 1H, J=7.3Hz), 6.90(d, 1H, J=10.6Hz), 1.23(s, 1H)24 3 CH.sub.3 S F 137 1762 1.80(m, 2H), 2.05(s, 3H), 2.51(m, 2H), 3.11 (m, 2H), 5.25(m, 1H), 6.76(d, J=7.3Hz, 1H), 6.90(d, J=10.6Hz, 1H), 11.22(br.s, 1H)25 3 CH.sub.3 (CH.sub.2).sub.3 O F 99 (KBr) (CDCl.sub.3)0.93(t, 3H, J=7.3Hz), 1.32-1.46(m, 1780, 1520 2H), 1.53-1.64(m, 2H), 1.92(tt, 2H, J=6Hz, 1110 6Hz), 3.22(dt, 2H, J=6Hz, 6Hz), 3.44(t, 2H, J=6.4Hz), 3.57(t, 2H, J=6Hz), 4.34(br, 1H), 6.63(d, 1H, J=7.0Hz), 6.81(d, 1H, J=9.9Hz), 9.42(br, 1H)26 3 CH.sub.3 (CH.sub.2).sub.3 S F 100-101 (CH.sub.2 Cl.sub.3) (CDCl.sub.3)0.91(t, 3H, J=7.2Hz), 1.34-1.63(m, 3470, 1780 4H), 1.93(m, 2H), 2.53(t, 2H, J=7Hz), 2.63(t, 1770, 1650 2H, J=7Hz), 3.26(br.s, 2H), 3.89(br.s, 1H), 6.52 (d, 1H, J=7.1Hz), 6.78(d, 1H, J=10.3Hz), 8.30(br.s, 1H)27 1 ##STR27## F 189-190 3440, 3220 1760, 1744 1730, 1.18-1.63(m, 6H), 1.98-2.09(m, 1H), 2.68-2.77 (m, 1H), 2.85-2.96(m, 1H), 4.33(d, 1H, J=4.4Hz), 4.48(dd, 1H, J=4.4Hz, 4.8Hz), 5.39 (br, 1H), 6.72(d, 1H, J=7.7Hz), 6.89(d, 1H, J=10.6Hz), 11.21(s, 1H)28 1 ##STR28## F 189-190 3440, 3220 1760, 1744 1730, 1.18-1.63(m, 6H), 1.98-2.09(m, 1H), 2.68-2.77 (m, 1H), 2.85-2.96(m, 1H), 4.33(d, 1H, J=4.4Hz), 4.48(dd, 1H, J=4.4Hz, 4.8Hz), 5.39 (br.s, 1H), 6.72(d, 1H, J=7.7Hz), 6.89(d, 1H, J=10.6Hz), 11.21(s, 1H)29 1 ##STR29## F 177-179 3460, 1762, 1652 (CDCl.sub.3)1.49(d, 1H, J=9.5Hz), 1.57- 1.89(m, 5H), 3.37(d, 2H, J=5.9Hz), 3.61(d, 1H, J=7.0Hz), 3.69(dd, 1H, J=2.8Hz, 7.0Hz), 4.39 (br.s, 1H), 6.63(d, 1H, J=7.3Hz), 7.98(d, 1H, J=10.3Hz), 8.42(br.s, 1H)30 1 ##STR30## F 254-255 (dec.) (KBr)1770, 1515, 945 1.56(br.d, 1H), J=11Hz), 1.98(br.d, 1H, J=7Hz), 2.17(dddd, 1H, J=13Hz, 13Hz, 13Hz, 4.5Hz), 3.17(br.d, 1H, J=13Hz), 3.25-3.36(m, 2H), 3.44-3.54(m, 2H), 3.99-4.09(m, 2H), 5.20 (br, 1H), 6.05(d, 1H, J=7.3Hz), 6.82(d, 1H, J=10.6Hz), 7.25-7.41(m, 5H), 10.4(br, 1H)31 1 ##STR31## F 199-200 (KBr)1760, 1510, 950 1.62-1.86(m, 2H), 2.05-2.18(m, 1H), 2.48-2.58 (m, 1H, overlaid by solvent), 2.62-2.80(m, 2H), 3.17(dd, 1H, J=11Hz, 11Hz), 3.42(ddd, 1H, J=11Hz, 11Hz, 2Hz), 3.93(dd, 1H, J=11Hz, 3.3Hz), 4.11(dd, 1H, J=11Hz, 4Hz), 5.08(br, 1H), 6.17(d, 1H, J=7.3Hz), 6.84(d, 1H, J=10.6Hz), 7.22 -7.39(m, 5H), 11.18(br, 1H)32 1 ##STR32## F 207-209 3440, 1772 1648, 1622 1520 1.22-1.78(m, 8H), 3.13(d, 2H, J=4.76Hz), 3.51 (dd, 1H, J=1.12Hz, 7.53Hz), 3.64(d, 1H, J= 7.35Hz), 4.22(t, 1H, J=5.36Hz), 5.06(br.s, 1H), 6.82(d, 1H, J=7.32Hz), 6.89(d, 1H, J=10.62Hz), 11.22(br.s, 1H)33 1 ##STR33## F 200-202 (methanol) 1757 (CDCl.sub.3 + DMSO-d.sub.6)1.43(s , 3H), 1.45(s, 3H), 1.92(m, 1H), 3.28(t, 2H, J=6.6Hz), 3.75(dd, 2H, J=5.1Hz, 12.2Hz), 4.04-4.16(m, 3H), 6.61 (d, 1H, J=7.3Hz), 6.74(d, 1H, J=10.5Hz), 0.71(br.s, 1H)__________________________________________________________________________
EXAMPLE 34 5-Fluoro-6-[(tetrahydro-4H-pyran-3-yl)methylamino]-2-benzoxazolin-2-one
To a solution of 6-(5,6-dihydro-2H-pyran-3-yl)methylamino)-5-fluoro-2-benzoxazolone (1.0 g, 3.88 mmole) in 100 ml methanol was added 50 mg platinum oxide and the mixture was hydrogenated at 1 atm. and room temperature for 1 hour. The mixture was filtered, the filtrate concentrated in vacuo and the resulting solid was washed with ethanol. Recrystallization from ethanol gave 0.48 g of the title compound (47%): m.p. 177°-178° C.
IR (KBr): 1760, 1510, 1090, 950 cm -1 .
NMR: 1.15-1.30 (m, 1H), 1.35-1.65 (m, 2H), 1.75-1.90 (m, 2H), 2.90-2.95 (m, 2H), 3.05-3.15 (m, 1H), 3.70-3.85 (m, 2H), 5.25 (br, 1H), 6.75 (d, 1H), 6.89 (d, 1H), 11.30 (br, 1H).
EXAMPLE 35
5-Fluoro-6-[(tetrahydropyran-2-yl)methylamino]benzoxazolin-2-one
In a like manner, employing 5-fluoro-6-[(3,4-dihydro-2H-pyran-2-yl)methylamino]benzoxazolin-2-one in the procedure of Example 34 afforded the title compound: m.p. 185°-186° C.
IR (CH 2 Cl 2 ): 3500, 1790, 1780 cm -1 .
NMR (CDCl 3 ): 1.36-1.67 (m), 1.89 (m, 1H), 3.04 (dd, 1H, J=8, 12 Hz), 3.16 (dd, 1H, J=3.5, 12 Hz), 3.42-3.61 (m, 2H), 4.03 (m, 1H), 4.27 (m, 1H), 6.62 (d, 1H, J=7.1 Hz), 6.78 (d, 1H, J=10.3 Hz), 8.52 (br.s, 1H).
EXAMPLE 36
5-Fluoro-6-[(1,2,3,4-tetrahydro-2-naphthyl)methylamino]benzoxazolin-2-one
In a manner similar to Example 3A starting with 5-fluoro-6-[(3,4-dihydro-2-naphthyl)methylamino]benzoxazolin-2-one but employing palladium carbon (5%) instead of platinum oxide, the title compound was prepared: m.p. 177°-178° C.
IR (KBr): 1770, 1660, 1520 cm -1 .
NMR: 1.30-1.50 (m, 1H), 1.90-2.10 (m, 2H), 2.49 (dd, 1H), 2.65-2.95 (m, 3H), 3.06 (dd, 2H), 5.36 (m, 2H), 6.79 (d, 1H), 6.93 (d, 1H), 11.21 (s, 1H).
EXAMPLE 37
5-Fluoro-6-[(chroman-3-yl)methylamino]benzoxazolin-2-one
In a manner similar to Example 34, starting with 5-fluoro-6-[(4-chloro-2H-chromene-3-yl)methylamino]benzoxazolin-2-one and hydrogenating it in the presence of triethylamine, the title compound was prepared: m.p. 223°-224° C.
IR (KBr): 1750, 1510, 1490 cm -1 .
NMR: 2.25-2.38 (m, 1H), 2.53-2.60 (m, 1H), 2.87 (dd, 1H), 3.06 (d, 1H), 3.09 (d, 1H), 3.87 (dd, 1H), 4.22-4.27 (m, 1H), 6.71-6.75 (m, 1H), 6.78-6.84 (m, 2H), 6.91 (d, 1H), 7.01-7.08 (m, 2H), 11.20 (br, 1H).
EXAMPLE 38
5-Methoxy-6-[(tetrahydropyran-3-yl)methylamino]benzoxazolin-2-one
Employing the procedure according to Example 34 with 5-methoxy-6-[(5,6-dihydro-2H-pyran-3-yl)methylamino]benzoxazolin-2-one afforded the title compound: m.p. 155° C (dec.).
IR (Nujol): 3200, 1780, 1740, 1680, 1640 cm -1 .
NMR: 1.20-1.25 (m, 1H), 1.42-1.60 (m, 2H), 1.72-1.91 (m, 2H), 2.87-2.94 (m, 2H), 3.08-3.15 (m, 1H), 3.69-3.81 (m, 6H), 6.58 (s, 1H), 6.62 (s, 1H), 11.09 (br.s, 1H).
EXAMPLE 39
5-Ethyl-6-[(tetrahydropyran-3-yl)methylamino]benzoxazolin-2-one
Employing the procedure according to Example 34 with 5-ethyl-6-[(5,6-dihydro-2H-pyran-3-yl)methylamino]benzoxazolin-2-one afforded the title compound: m.p. 148°-° C.
IR (Nujol): 3200, 2750, 1775, 1630 cm -1 .
NMR: 1.25-1.30 (m, 1H), 1.86-2.00 (m, 4H), 2.04 (s, 3H), 2.91-2.95 (m, 2H), 3.13-3.17 (m, 2H), 3.72 (br.s, 1H), 3.84 (br.s, 1H), 5.01-5.03 (m, 1H), 6.40 (s, 1H), 6.43 (s, 1H).
EXAMPLE 40
5-Fluoro-6-[(2,6-dimethyltetrahydropyran-3-yl)methylamino]benzoxazolin-2-on
Employing the procedure according to Example 34 with 5-fluoro-6-[(2,6-dimethyldihydro-2H-pyran-3-yl)methylamino]benzoxazolin-2-one afforded the title compound: m.p. 123°-139° C. (methanol).
IR (Nujol): 1757, 1788 cm -1 .
NMR (CDCl 3 ): 1.22 (d, 3H, J=6.1 Hz), 1.27 (d, 3H, J=6.6 Hz), 1.44 (m, 2H), 1.77 (m, 2H), 1.90-2.06 (m, 1H), 3.17-3.39 (m, 2H), 3.55 (m, 1H), 3.77 (m, 1H), 4.03 (br.s, 1H), 6.61 (d, 1H, 7.1 Hz), 6.79 (d, 1H, J=10.3 Hz), 8.70 (br.s, 1H).
EXAMPLE 41
5-Fluoro-6-[(tetrahydrothiopyran-3-yl)methylamino]benzoxazolin-2-one
Employing the procedure according to Example 34 with 5-fluoro-6-[(dihydro-2H-thiopyran-3-yl)methylamino]benzoxazolin-2-one afforded the title compound.
EXAMPLE 42
5-Fluoro-6-[(1-oxo-tetrahydrothiopyran-3-yl)methylamino]benzoxazolin-2-one
Alumina-supported sodium metaperiodate [K. T. Liu and Y. C. Tong, J.O.C. 43:2717 (1989)] (5.6 g) was added to a solution of 1.2 g (4.25 mmole) 5-fluoro-6-[(tetrahydrothiopyran-3-yl)methylamino]benzoxazolin-2-one in 200 ml ethanol and 50 ml THF. The mixture was stirred for 20 hours at room temperature. The alumina was filtered off and the solvent was removed in vacuo. The crude product was purified by silica gel column chromatography, eluting with ethyl acetate/THF/methanol (80:20:5), and recrystallized from methanol/diethyl ether to give the title compound (0.28 g, 22% yield).
IR (KBr): 1765, 1520, 1020, 940 cm -1 .
NMR: 1.1-1.25 (m, 1H), 1.4-1.55 (m, 1H of one isomer, E or Z at 1,3 position of tetrahydrothiopyran-1-oxide ring), 1.65-2.15 (m, 3H), 2.3-2.6 (m, 2H+1H of one isomer), 2.75-2.85 (m, 1H of one isomer), 2.9-3.15 (m, 2H of one isomer), 5.4-5.55 (m, 1H), 6.77-6.85 (m, 1H), 6.91 (d, 1H, J=10.6 Hz), 11.2 (br, 1H).
EXAMPLE 43
5-Fluoro-6-[3-(butylsulfinyl)propylamino]benzoxazolin-2-one
Employing the procedure according to Example 42 with 5-fluoro-6-[3-(butylthio)propylamino]benzoxazolin-2-one afforded the title compound: m.p. 116°-117° C. (methanol).
IR (CH 2 Cl 2 ): 3480, 1780, 1660 cm -1 .
NMR: 0.90 (t, 3H, J=7.3 Hz), 1.40 (m, 2H), 1.60 (m, 2H), 1.91 (m, 2H), 2.57-2.88 (m, 4H), 3.18 (m, 2H), 5.38 (m, 1H), 6.79 (d, 1H, J=7.3 Hz), 6.90 (d, 1H, J=11.0 Hz), 11.23 (br.s, 1H).
EXAMPLE 44
R-5-Fluoro-6-[(tetrahydropyran-3-yl)methylamino]-benzoxazolin-2-one
To a solution of 5.04 g (30.0 mmol) of 6-amino-5-fluoro-benzoxazolin-2-one in 100 ml methanol was added 4.04 g of (S)-tetrahydropyran-3-yl-carboxaldehyde as an oil, prepared as described in Preparation L, below, at room temperature. Then, 4.0 ml acetic acid and 1.9 g (30.2 mmol) of sodium cyanoborohydride were added to the solution and the mixture was stirred for 1.5 hours. The solvent was evaporated down and water was added to the residue. The resulting solids were collected by filtration and dried at 50° C. under vacuum. Recrystallization of the crude product from methanol afforded 4.075 g of the title compound.
IR(CH 2 Cl 2 ): 3500, 1790, 1780 cm -1 .
NMR(CDCl 3 ): 1.36-1.67 (m), 1.89 (m, 1H), 3.04 (dd, 1H, J=8, 12 Hz), 3.16 (DD, 1H, J=3.5, 12 Hz), 3.42-3.61 (m, 2H), 4.03 (m, 1H), 4.27 (m, 1H), 6.62 (d, 1H, J=7.1Hz), 6.78 (d, 1H, J=10.3 Hz), 8.52 (br.s, 1H).
EXAMPLE 45
S-5-Fluoro-6-[(tetrahydropyran-3-yl)methylamino]-benzoxazolin-2-one
Employing the procedure according to Example 44 with (R)-tetrahydropyran-3-yl-carboxaldehyde prepared as described in Preparation M, below, affords the title compound.
EXAMPLE 46
Starting with the appropriate aldehydes and variously substituted 6-amino-2-benzoxazolones and employing the procedure of Example 7, the following compounds are prepared:
______________________________________ ##STR34##n R R.sub.1______________________________________ ##STR35## 5-CH.sub.3 O ##STR36## 5-CH.sub.3 O1 ##STR37## 5-CH.sub.3 O ##STR38## H1 ##STR39## H1 ##STR40## 4-CH.sub.31 ##STR41## 5-CF.sub.32 ##STR42## 7-Cl2 ##STR43## ##STR44##2 CH.sub.3CH.sub.2CH.sub.2S 5-F2 CH.sub.3CH.sub.2CH.sub.2S 5-F2 CH.sub.3CH.sub.2CH.sub.2S 5-F3 CH.sub.3CH.sub.2CH.sub.2S H1 CH.sub.3CH.sub.2O 7-Cl1 CH.sub.3CH.sub.2S 7-Cl______________________________________
PREPARATION A
6-Amino-5-fluorobenzoxazolin-2-one
A.1 4-Fluoro-2-nitrophenol
To a mechanically stirred solution of 400 ml concentrated nitric acid, at 0° C., was added dropwise a solution of 4-fluorophenol (204 g, 1.8 mole) in acetic acid (200 ml) over 2 hours. Stirring was continued for another 2 hours at 5° C. The reaction mixture was poured onto ice, and the resulting yellow solids were collected and washed with water. The solids were recrystallized from methanol-water (5:1) to afford 198 g of the title compound. The NMR spectrum showed absorption at 7.17 (dd, 1H, J=9, 5 Hz), 7.44-7.52 (m, 1H) and 7.80 (dd, 1H, J=8, 3 Hz).
A.2 2-Amino-4-fluorophenol
To a solution of 4-fluoro-2-nitrophenol (48.3 g, 0.30 mole) in 300 ml ethanol was added 0.24 g platinum oxide under nitrogen atmosphere. The mixture was hydrogenated with a Parr shaker for 8 hours at 45 psi. The catalyst was filtered off and the filtrate was concentrated to leave 40.5 g of the title compound as a brown powder. The NMR spectrum showed absorption at 4.79 (br.s, 2H), 6.11 (m, 1H), 6.36 (dd, 1H, J=11, 3 Hz), 6.53 (dd, 1H, J=5, 9 Hz) and 8.89 (s, 1H).
A.3 5-Fluorobenzoxazolin-2-one
To a solution of 2-amino-4-fluorophenol (40.5 g, 0.32 mole) in 400 ml tetrahydrofuran, at 0° C., was added dropwise trichloromethyl chloroformate (44.8 ml, 0.32 mole). The reaction mixture was allowed to warm up to room temperature Stirring was continued for 2 hours. Then, the reaction mixture was poured onto ice and the organic substance was extracted with ethyl acetate (500 ml×3). The combined extracts were washed with saturated sodium bicarbonate solution, dried over magnesium sulfate and concentrated to yield 44.3 g of the title compound as brown solids.
The NMR spectrum showed absorption at 6.86-6.90 (m, 1H), 7.01 (dd, 1H, J=8 3 Hz), 7.30 (dd, 1H, J=9, 5 Hz) and 11.82 (br.s, 1H).
A.4 5-Fluoro-6-nitrobenzoxazolin-2-one
To a stirred solution of 300 ml concentrated nitric acid, at room temperature, was added portionwise 73.2 g (0.48 mole) of 5-fluorobenzoxazolin-2-one. The reaction mixture was warmed to 50° C., and was stirred for 4 hours. After cooling, the reaction mixture was poured onto ice. The precipitate which formed was collected, washed with water, and dried to give 72.8 g of the title compound as a brown powder: m.p. 207°-209° C.
IR (Nujol): 3300, 1810, 1780, 1630 cm -1 .
NMR: 7.35 (d, 1H, J=11.0 Hz), 8.16 (d, 1H, J=6.6 Hz), 12.6 (br.s, 1H).
A.5 6-Amino-5-fluorobenzoxalin-2-one
To a solution of 5-fluoro-6-nitro-benzoxazolin-2-one (20 g, 0.1 mole) in 300 ml tetrahydrofuran was added 2 g palladium carbon (5%) under nitrogen atmosphere. The mixture was hydrogenated with a Parr shaker for 10 hours at 45 psi. The precipitate which resulted from hydrogenation was redissolved by adding tetrahydrofuran. The catalyst was removed by filtration and the filtrate was concentrated to give 18.1 g of the title compound as a brown solid: m.p. 180°-182° C. (dec.).
IR (Nujol): 3400, 3280, 1750, 1630 cm -1 .
NMR: 4.93 (br.s, 2H), 6.71 (d, 1H, J=7.3 Hz), 6.84 (d, 1H, J=10 Hz), 11.2 (br.s, 1H).
PREPARATION B
6-Amino-5-ethylbenzoxazolin-2-one
5-Ethyl-2-benzoxazolone was prepared via the condensation of 2-amino-4-ethylphenol with urea according to the procedure of W. J. Closs et al., J. Am. Chem. Soc., 71, 1265 (1949). In a manner similar to Preparation A, starting with 5-ethylbenzoxazolin-2-one, 6-amino-5-ethylbenzoxazol was prepared: m.p. 146°-147° C.
IR (Nujol): 3430, 3340, 3130, 1710, 1640 cm -1 .
NMR: 1.10 (t, 3H, J=7.3 Hz), 2.43 (q, 2H, J=7.3 Hz), 4.73 (br.s, 2H), 6.56 (s, 1H), 6.64 (s, 1H), 10.99 (br.s, 1H).
PREPARATION C
The procedure of Preparation A is employed to prepare 6-amino-4-methylbenzoxazolin-2-one, 6-amino-5-methylbenzoxazolin-2-one, 6-amino-5-trifluoromethylbenzoxazolin-2-one, 6-amino-5-methoxybenzoxazolin-2-one, -amino-5-methylthiobenzoxazolin-2-one, 6-amino-5-phenoxybenzoxazolin-2-one, 6-amino-5-phenylthiobenzoxazolin-2-one, 6-amino-7-chlorobenzoxazolin-2-one and 6-amino-7-fluorobenzoxazolin-2-one.
PREPARATION D
3-(Tetrahydropyran-3-yl)propionaldehyde
D.1 Ethyl-3-(5,6-dihydro-2H-pyran-3-yl)acrylate
To a stirred suspension of sodium hydride (60% in mineral oil; 1.43 g, 35.7 mmoles) in 50 ml tetrahydrofuran, at room temperature, was added dropwise triethyl phosphonoacetate (8.35 g, 37.2 mmoles) under a nitrogen atmosphere. The reaction mixture was stirred for 15 minutes. To this was added dropwise a solution of 3.34 g (29.8 mmoles) of 3-formyl-5,6-dihydro-2H-pyrane (Japan Kokai 59-167,584 to BASF) in 20 ml tetrahydrofuran. The resulting mixture was stirred for 1 hour. The reaction was quenched by adding acetic acid. Then, the reaction mixture was concentrated and an aqueous sodium bicarbonate solution was added. The organic substance was extracted with ethyl acetate The extract was washed with brine, dried over magnesium sulfate and evaporated to an oil. The crude oil was purified by column chromatography on silica gel eluted with 25% ethyl acetate-hexane to yield 3.1 g of the title compound.
The NMR spectrum showed absorption at 1.26-1.38 (m, 3H), 2.34 (br., 2H), 3.8 (t, 2H, J=5 Hz), 4.15-4.30 (m, 4H), 5.63 (d, 1H, J=17 Hz), 6.28 (br., 1H) and 7.21 (d, 1H, J=17 Hz).
D.2 Ethyl-3-(tetrahydro-2H-pyran-3-yl)propionate
A solution of ethyl-3-(5,6-dihydro-2H-pyran-3-yl) acrylate (3.1 g) in 50 ml methanol was hydrogenated over 0.15 g of palladium carbon (5%) at room temperature under a hydrogen atmosphere. The catalyst was removed by filtration and the filtrate was concentrated to yield a crude oil. The crude product was purified by column chromatography on silica gel eluted with 50% ethyl acetate-hexane to give 3.0 g of the title compound.
The NMR spectrum showed absorption at 1.10-1.20 (m, 1H), 1.26 (t, 3H, J=7 Hz), 1.45-1.63 (m, 5H), 1.82-1.91 (m, 1H), 2.27-2.34 (m, 2H), 3.06 (dd, 1H, J=9.5, 11 Hz), 3.30-3.40 (m, 1H), 3.83-3.89 (m, 2H) and 4.13 (q, 2H, J=7 Hz).
D.3 3-(Tetrahydro-2H-pyran-3-yl)propionaldehyde
To a solution of ethyl-3-(tetrahydro-2H-pyran-3-yl)propionate (3.0 g) was, at -78° C., added dropwise DIBAL (16 ml of 1.5 mole toluene solution) under a nitrogen atmosphere. Stirring was continued for one hour. The reaction was quenched by adding a methanol-water mixture. The resulting solution was allowed to warm up to room temperature. The solids which formed were removed. The filtrate was dried over magnesium sulfate and concentrated to yield a crude oil. The crude product was purified by distillation to yield 2.0 g of the title compound.
The NMR spectrum showed absorption at 1.09-1.28 (m, 1H), 1.42-1.65 (m, 5H), 1.80-1.91 (m, 1H), 2.42-2.49 (m, 2H), 3.07 (dd, 1H, J=9, 11 Hz), 3.31-3.40 (m, 1H), 3.84-3.89 (m, 2H) and 9.78 (s, 1H).
PREPARATION E
3-Methylcyclohexanecarboxaldehyde
E.1 3-Methylcyclohexanecarboxylic acid
To a solution of m-toluic acid (13.6 g, 0.1 mole) in acetic acid was added platinum oxide (0.1 g) under nitrogen. The mixture was hydrogenated in a Parr shaker at 35 psi. Upon completion, the catalyst was removed by filtration and the filtrate was concentrated to dryness to give 12 g of the title compound. The NMR spectrum showed absorption at 0.84 (d, 3H), 0.90 (d, 3H), 0.99-1.13 (m, 1H), 2.21-1.46 (m, 3H), 1.54-1.65 (m, 3H), 1.70-1.98 (m, 2H) and 1.23-2.41 (m, 1H).
E.2 1-Hydroxymethyl-3-methylcyclohexane
To a boran-methyl sulfide complex (1.7 ml, 0.028 mole) in 7 ml tetrahydrofuran, at 0° C., was added dropwise 2 g of 3-methylcyclohexanecarboxylic acid (0.014 mole) in 7 ml tetrahydrofuran. Stirring was continued for one hour. The reaction mixture was diluted with ether and washed with 1N aqueous sodium hydroxide and then with brine. Concentration and distillation gave 1.34 g of the title compound The NMR spectrum showed absorption at 0.54-0.74 (m, 1H), 0.90, 0.93 (s, 3H), 1.17-1.53 (m, 3H), 1.65-1.77 (m, 3H) and 3.39-3.52 (m, 2H).
E.3 3-Methylcyclohexanecarboxaldehyde
To a solution of 1-hydroxymethylcyclohexane (6.8 g, 0.053 mole) in 150 ml dichloromethane was added pcc (22.9 g, 0.106 mole) under nitrogen. Stirring continued for 1 hour at room temperature. The solids were removed by filtration through Florisil and the filtrate was concentrated to give 8 g of the title compound. The NMR spectrum showed 0.90, 0.95 (d, 3H, J=8 Hz), 0.86-2.32 (m, 10H), and 9.68, 9.70 (d, 1H, J=2 Hz).
PREPARATION F
Endo-7-Oxabicyclo(2,2,1)heptane-2-carboxaldehyde
Using the procedure of Preparation D3 endo-2-carbomethoxy-7-oxabicyclo(2,2,1)heptane (M. P. Kunstmann et al., J. Am. Chem. Soc., 84, 4115 (1962); 2.13 g, (12.5 mmoles) was reduced to the title compound (1.51 g).
The NMR spectrum showed absorption at 1.46-1.95 (m, 6H), 3.07 (m, 1H), 4.68 (m, 1H), 4.86 (dd, 1H, J=5.6, 5.6 Hz) and 9.73 (d, 1H, J=1.5 Hz). In like manner exo-2-carbomethoxy-7-oxabicyclo(2,2,1)heptane was reduced to the corresponding exo-7-oxabicyclo(2,2,1)heptane-2-carboxaldehyde.
PREPARATION G
5-Fluoro-6-[(4-chloro-2H-chromen-3-yl)methylamino]benzoxazolin-2-one
G.1 4-Chloro-3-formyl-2H-chromene
The title compound was prepared according to the procedure of J. A. Vigilio et al., Organic Preparations and Procedures Inc., 14, 9 (1982).
G.2 5-Fluoro-6-[(4-chloro-2H-chromen-3-yl)methylamino]benzoxazolin-2-one
To a solution of 6-amino-5-fluorobenzoxazolin-2-one (2.02 g, 12 mmole) in ethanol (100 ml) was combined the product of G.1 (2.53 g, 13 mmole). The mixture was stirred at room temperature for 6 hours. The reaction mixture was then concentrated in vacuo to yield solids. The solid product was washed with ethanol. This product was dissolved in methanol (150 ml) and sodium borohydride was added in portions at room temperature. Stirring was continued for hours. The reaction mixture was concentrated and aqueous ammonium chloride was added. The organic material was extracted with ethyl acetate/THF. The combined extracts were washed with brine, dried over magnesium sulfate and concentrated. The residue was chromatographed on silica gel, eluted with ethyl acetate/hexane (1:3) to afford the crude product, which was recrystallized from ethanol to give 0.90 g of the title compound (22%): m.p. 197° C. (dec.).
PREPARATION H
6-Oxabicyclo[3.2.1]oct-1'-ylmethanol
H.1 6-Oxabicyclo[3.2.1]oct-1'-ylmethanol
A mixture of 3-cyclohexene-1,1-dimethanol (10.0 g, 70 mmol; Aldrich Chemical Company, Inc.) and NBS (13.7 g, 77 mmol) in 200 ml dichloromethane was stirred for 13 hours at room temperature. Then, the reaction mixture was washed with water (2×100 ml) and brine and dried over Na 2 SO 4 . The solvent was removed by evaporation to give a pale yellow oil (17.0 g). To a mixture of this oil and 20 ml toluene were added ALBN (0.2 g) and then n-tributyltinhydride (21.5 g, 84 mmol) with stirring. The mixture was heated to 110° C. and stirred for 1.5 hours. Silica gel chromatography of the product (150 g, 50% ethyl acetate/hexane, twice) gave the title compound (7.75 g, 77% yield).
The NMR spectrum (CDCl 3 ) showed absorption at 1.28-1.52 (m, 3H), 1.66-1.84 (m, 6H), 3.57 (dd, 2H, J=1.84 Hz, 5.50 Hz), 3.65 (dd, 1H, J=1.84 Hz, 7.69 Hz), 3.84 (d, 1H, J=7.69 Hz), 4.40 (t, 1H, J=5.31 Hz).
H.2 6-Oxabicyclo[3.2.1]oct-1'-ylcarboxaldehyde
A mixture of 6-oxabicyclo[3.2.1]oct-1'-ylmethanol (3.55 g, 25 mmol), pcc (8.08 g, 37.5 moles) and 100 ml dichloromethane was stirred at room temperature for one hour. The resulting mixture was diluted with 100 ml diethylether and filtered through silica gel. The silica gel was washed with diethylether (7×100 ml). The filtrate and washings were combined, the solvent was removed by evaporation to give the title compound (3.00 g, 86% yield).
The NMR spectrum (CDCl 3 ) showed absorption at 1.29-1.40 (m, 1H), 1.57-1.90 (m, 6H), 2.19-2.26 (m, 1H), 3.89 (d, 1H, J=8.4 Hz), 4.03 (dd, 1H, J=1.8 Hz, 8.4 Hz), 4.53 (dd, 1H, J=4.8 Hz, 5.9 Hz), 9.56 (s, 1H).
PREPARATION I
(1S,2R,4R)-7-oxabicyclo[2.2.1]heptan-2-carboxaldehyde
I.1 (4S)-3-[(1S,2R,4R)-7-oxabicyclo[2.2.1]hept-2-ylcarbonyl]-4-isopropyloxazolidin-2-one and (4S)-3-[(1R,2S,4S)-7-oxabicyclo[2.2.1]hept-2-ylcarbonyl]-4-isopropyloxazolidin-2-one
A stirred, cooled (-78° C.) solution of 7.75 g (60 mmol) of (4S)-4-isopropyloxazolidin-2-one in 200 ml of THF was metalated with 44 ml of n-butyllithium (1.49M in hexane, 65 mmol). To the reaction was then added racemic exo-oxabicyclo[2.2.1]heptan-2-carboxyl chloride prepared from 8.95 g (63 mmol) of the corresponding racemic acid and oxalyl chloride. The reaction mixture was warmed to 0° C. and stirred for one hour. Excess acid chloride was hydrolyzed by the addition of 50 ml of 1M aqueous potassium carbonate followed by stirring of the mixture for one hour at room temperature. Organic solvent was removed under reduced pressure. The resulting product was diluted with 200 ml of water and extracted with dichloromethane (4×200 ml). The combined organic extracts were successively washed with water (200 ml) and brine (200 ml), dried over anhydrous magnesium sulfate and concentrated in vacuo to give 18.0 g of a pale yellow oil. Separation of the diastereomeric imides was accomplished on a Waters Prep LC/System 500A using two Prep-PAK-500/silica cartridges (57 mm×30 cm, ether/n-hexane (1:5), flow rate 250 ml/min.) in three runs. The retention times of the less polar imide and the more polar imide were 16 and 22 minutes, respectively. The less polar imide (6.47 g), which contained an unknown impurity, was purified by recrystallization from ether-hexane to give 4.47 g (29% yield) of the pure, less polar imide, (4S)-3-[(1S,2R,4R)-7 -oxabicyclo[2.2.1]hept-2-ylcarbonyl]-4-isopropyloxazolidin-2-one, ( > 99% de). The structure of the less polar imide was determined by X-ray analysis using crystal obtained by another slow recrystallization from ether-hexane. The more polar imide (4S)-3-[(1R,2S,4S)-7-oxabicyclo[2.2.1]hept-2-ylcarbonyl]-4-isopropyloxazolidin-2-one, (6.36 g, 42% yield, 98.5% de) was used without further purification.
I.2 Methyl(1S,2R,4R)-7-oxabicyclo[2.2.1]heptan-2-carboxylate
To a cooled (0° C.) solution of (4S)-3-[(1S,2R,4R)-7-oxabicyclo[2.2.1]hept-2-ylcarbonyl]-4-isopropyloxazolidin-2-one (4.35 g, 17 mmol) in 350 ml of THF was added slowly and dropwise, with stirring, an aqueous lithium hydrogen peroxide solution (prepared from 15 ml of 30% aqueous hydrogen peroxide, 1.28 g (30 mmol) of lithium hydroxide and 120 ml of water). After stirring for one hour at 0° C., the reaction was quenched by dropwise addition of 300 ml of 2N sodium sulfite. After stirring the resulting slurry for 15 minutes at 0° C., the mixture was basified with saturated sodium bisulfite and the organic solvent was removed in vacuo. The remaining aqueous mixture was washed with 200 ml of dichloromethane After acidification with concentrated HCl, the chiral acid was extracted ten times with 300 ml of dichloromethane. The combined organic phases were dried over magnesium sulfate and concentrated in vacuo to give the unpurified acid as a pale-yellow oil. The unpurified acid was diluted with 100 ml of ether and treated with excess diazomethane in ether. After 15 minutes, the excess diazomethane was removed by bubbling nitrogen through the solution. The resulting solution was concentrated under reduced pressure and purified by flash chromatography [100 g of silica gel, ether/hexane (1:1 )] to give 2.03 g (76% yield) of the title compound as a clear volatile oil. An analytical sample was purified by Kugelrohr distillation: b.p. 106°-109° C./0.9 mm Hg.
IR (Nujol): 3000, 2970, 2880, 1736, 1064, 1002, 938 cm -1 .
NMR (CDCl 3 ): 1.42-1.55 (m, 2H), 1.67-1.80 (m, 3H), 2.09-2.17 (m, 1H), 2.61 (dd, 1H, J=4.9 Hz, 9.1 Hz), 3.70 (s, 3H), 4.66 (dd, 1H, J=4.9 Hz, 5.1 Hz), 4.84 (d, 1H, J=4.9 Hz).
[α] D 20 : +31 3° (c1.00, methanol).
I.3 (1S,2R,4R)-7-oxabicyclo[2.2.1]heptan-2-carboxaldehyde
Using the procedure of Preparation D.3, methyl (1S,2R,4R)-7-oxabicyclo[2.2.1]heptan-2-carboxylate was converted to the title compound. The NMR spectrum (CDCl 3 ) showed absorption at 1.46-1.95 (m, 6H), 3.07 (m, 1H), 4.68 (m, 1H), 4.86 (dd, 1H, J=5.6 Hz, 5.6 Hz), 9.73 (d, 1H, J=1.5 Hz).
PREPARATION J
(1R,2S,4S)-7-oxabicyclo[2.2.1]heptan-2-carboxaldehyde
J.1 Methyl(1R,2S,4S)-7-oxabicyclo[2.2.1]heptan-2-carboxylate
Employing the procedure according to Preparation I.2 with (4S)-3-[(1R,2S,4S)-7-oxabicyclo[2.2.1]hept-2-ylcarbonyl]-4-isopropyloxazolidin-2-one afforded the title compound (96% yield): b.p. 94°-98° C./0.5 mm Hg.
IR (Nujol): 3000, 2970, 2880, 1736, 1064, 1002, 938 cm -1 .
NMR (CDCl 3 ): 1.42-1.55 (m, 2H), 1.67-1.80 (m, 3H), 2.09-2.17 (m, 1H), 2.61 (dd, 1H, J=4.9 Hz, 9.1 Hz), 3.70 (s, 3H), 4.66 (dd, 1H, J=4.9 Hz, 5.1 Hz), 4.84 (d, 1H, J=4.9 Hz).
[α] D 20 : -29.8° (c1.00, methanol).
J.2 (1R,2S,4S)-7-oxabicyclo[2.2.1heptan-2-carboxaldehyde
Using the procedure of Preparation D.3, methyl (1R,2S,4S)-7-oxabicyclo[2.2.1]heptan-2-carboxylate was converted to the title compound. The NMR spectrum (CDCl 3 ) showed absorption at 1.46-1.95 (m, 6H), 3.07 (m, 1H), 4.68 (m, 1H), 4.86 (dd, 1H, J=5.6 Hz, 5.6 Hz), 9.73 (d, 1H, J=1.5 Hz).
PREPARATION K
2-Oxabicyclo[2.2.1]hept-4-ylmethanol
To a mixture of 3-cyclopenten-1,1-dimethanol, prepared according to J-P. Depres, et al., J. Org. Chem. 49:928 (1984) and H. Paulsen, et al., Chem. Ber. 144:346 (1981), (3.74 g, 29 mmol), 100 ml of dichloromethane and 100 ml THF was added NBC (5.71 g, 32 mmol) with stirring at 0° C. After addition of NBS was completed, the ice-bath was removed and the reaction mixture was stirred at room temperature. After 2.5 hours, another portion of NBS (5.71 g, 32 mmol) was added and the reaction mixture was stirred for an additional one hour at room temperature. The reaction mixture was then partitioned between 200 ml of CHCl 3 and 200 ml of water. The aqueous phase was extracted with 100 ml CHCl 3 . The combined organic phases were washed with 0.5N Na 2 SO 4 and then with brine, dried over MgSO 4 and evaporated. The residual oil was applied to a silica gel column (150 g) and eluted with 33% ethyl acetate/hexane to about 50% ethyl acetate/hexane. Fractions containing the desired product as a main component were combined. Evaporation of the solvent gave 3.47 g of a pale yellow oil. A mixture of the oil, tri-n-butyltinhydride (5.44 g, 18.7 mmol), ALBN (0.05 g) and 4 ml toluene was refluxed for 80 minutes. Silica gel column chromatography (150 g, 50% ethyl acetate/hexane to about 67% ethyl acetate/hexane) gave the title compound (1.10 g).
The NMR spectrum (CDCl 3 ) showed absorption at 1.41 (d, 1H, J=9.5 Hz), 1.54-1.79 (m, 5H), 3.67 (dd, 1H, J=2.8 Hz, 6.8 Hz), 3.83 (s, 2H), 4.36 (s, 1H).
PREPARATION L
(S)-Tetrahydropyran-3-yl-carboxaldehyde
L.1 Diethyl(2S,3R)-3-allyl-2-hydroxysuccinate
Employing the procedures of D. Seebach et al., Helv. Chim. Act. 60: 301 (1979) and D. Seebach et al., Org. Synth. 63: 109 (1985) and starting with S-malic acid allylation was carried out with allylbromide on a 34 g scale. The resulting diastereomeric mixture (3:4=10:1) was purified by medium pressure column chromatography using 1 kg of silica gel and 15% ethyl acetate/hexane. The same scale reaction was repeated and the impure fraction from both were combined and purified again using the same chromatographic procedure to yield 35.06 g (43%) of the anti-diastereomer diethyl (2S,3R)-3-allyl-2-hydroxysuccinate.
L.2 (2S,3S)-3-Allyl-2-(methoxymethyl)oxy-1,4-butanediol
To a solution of 21.78 g (94.7 mmol) of diethyl (2S,3R)-3-allyl-2-hydroxysuccinate in 500 ml methylal were added 15 g molecular sieves 4A and 5.23 g Amberlyst 15. To the reaction vessel was attached an addition funnel containing 150 ml of molecular sieves 4A. The reaction mixture was heated at reflux. After 4 hours, the molecular sieves 4A in the funnel were replaced with 150 ml of fresh molecular sieves 4A and heating of the reaction was continued for an additional 4 hours. The reaction mixture was filtered through Celite and concentrated in vacuo to provide 25.34 g of the diethyl ester in the MOM protected form. The MOM-protected diethyl ester was slowly added to a suspension of LAH (4.90 g, 129 mmol) in 500 ml tetrahydrofuran at room temperature. The addition was controlled so as to maintain the reaction temperature at around 35° C. After the addition was completed, stirring was continued for 1 hour. Then, the reaction was quenched with wet tetrahydrofuran followed by addition of a saturated aqueous solution of Rochelle salt. The reaction mixture then was filtered through Celite and the filtrate was concentrated in vacuo to afford 17.2 g of the corresponding MOM-protected diol, (2S,3S)-3-allyl-2-(methoxymethyl)oxy-1,4-butanediol. Using the above described procedures in another run, 12.41 g of (2S,3S)-3-allyl-2-(methoxymethyl)oxy-1,4-butanediol was obtained from 15.99 g of the starting diethyl ester. The (2S,3S)-3-allyl-2-(methoxymethyl)oxy-1,4-butanediol obtained from the two runs were combined and purified by medium pressure column chromatography using 1 kg silica gel, 66% ethylacetate/hexane, 100% ethyl acetate, to yield 24.11 g of (2S,3S)-3-allyl-2-(methoxymethyl)oxy-1,4-butanediol.
L.3 (2S,3S)-2-(Methoxymethyl)oxy-3-(3-tosyloxypropyl)-1,4-butanediol dibenzoate
To a solution of 22.13 g (116 mmol) of (2S,3S)-3-allyl-2-(methoxymethyl)oxy-1,4-butanediol in 100 ml pyridine was added 27.5 ml (237 mmol) of benzoyl chloride at room temperature. The reaction was exothermic and was completed in 1 hour. Most of the solvent was removed under vacuum, and the residue was acidified with diluted HCL (1N) and extracted with ether. The organic phase was washed with aqueous sodium bicarbonate and brine and then dried over sodium sulfate. Evaporation of the solvent yielded 47.8 g of the corresponding crude dibenzoate. The crude dibenzoate was azeotropically dried with benzene and dissolved in 360 ml of tetrahydrofuran. Then, 9.0 ml (10.0M) of borane-methylsulfide complex was added to the solution at 5° C. and then the mixture was stirred at room temperature for 2 hours. The reaction was then quenched with methanol and 21.5 g (286 mmol) of trimethylamine N-oxide dihydrate was added. The solvent was replaced by 400 ml of xylene and the solution was heated at reflux for 20 minutes. The reaction mixture then was diluted with ether, washed with brine and dried over sodium sulfate. The solvent was evaporated under vacuum to afford the corresponding alcohol which was combined with the alcohol obtained from another run starting with 1.98 g (10.4 mmol) of (2S,3S)-3-allyl-2-(methoxymethyl)oxy-1,4-butanediol. In 400 ml of methylene chloride were dissolved the combined alcohol produced above, 24.5 g (138 mmol) p-toluenesulfonyl chloride and 53 ml (380 mmol) triethylamine. Then, 1.62 g (13.3 mmol) of 4-dimethylaminopyridine was added to the solution and the reaction mixture was stirred overnight. The resultant mixture was partitioned between water and ether and the organic phase was washed with brine and dried over sodium sulfate. The solvent was evaporated and the crude residue was subjected to medium pressure column chromatography using silica-gel and 28% ethyl acetate/hexane to afford 47.3 g of (2S,3S)-2-(methoxymethyl)oxy-3-(3-tosyloxypropyl)-1,4-butanediol dibenzoate.
L.4 (2S)-2-[(3S)-Tetrahydropyran-3-yl ]-2-(methoxymethyl)oxyethanol
In 600 ml of tetrahydrofuran, containing 3.3 ml methanol were dissolved 47.3 g (82.3 mmol) of (2S,3S)-2-(methoxymethyl)oxy-3-(3-tosyloxypropyl)-1,4-butanediol dibenzoate and the solution was chilled in an ice-bath. To the solution were added, portionwise, 20.65 g (184 mmol) of potassium t-butoxide and the reaction mixture was stirred at room temperature for 2.5 hours. Then, an additional 2.46 g (22 mmol) of potassium t-butoxide and 150 μl of water were added and the reaction was stirred for an additional 30 minutes. Finally, 6 ml of water was added and the mixture was further stirred for 2 hours. The reaction mixture then was poured into a mixture of water and ethyl acetate. The aqueous phase was extracted four times with ethyl acetate and twice with 10% isopropanol-methylene chloride. The organic extracts were combined, dried over magnesium sulfate, carefully concentrated and purified by medium pressure column chromatography using silica gel and 72% ethyl acetate/hexane, 100% ethylacetate. The resulting compound, (2S)-2-[(3S)-tetrahydropyran-3-yl]-2-(methoxymethyl)oxyethanol, was found to be volatile. Thus, evaporation of the solvent was carefully carried out with an aspirator below room temperature. Pure fractions were collected and combined to yield 9.82 g of (2S)-2-[(3S)-tetrahydropyran-3-yl]-2-(methoxymethyl)oxyethanol contaminated with ethyl acetate (34%) as judged by 270 MHz 1 H-NMR.
L5. (S)-Tetrahydropyran-3-yl-carboxaldehyde
To a solution of 8.7 g (33 mmol, 66% purity) of (2S)-2-[(3S)-tetrahydropyran-3-yl]-2-(methoxymethyl)oxyethanol in 77 ml of water and 6.0 ml methanol was added 8.0 g of Amberlyst 15. The resultant mixture was heated at 65° C. with stirring for 1 hour. The Amberlyst 15 was removed by filtration through Celite and washed with ether and methanol. Then, most of the ether and methanol in the filtrate were distilled off at atmospheric pressure and the residual water was azeotropically removed with benzene. The resulting solution was concentrated down to about 200 ml and 16.3 g (33.1 mmol, 90% purity) of lead tetraacetate was added to the solution cooled in an ice-bath. The reaction mixture was warmed to room temperature and stirred for 45 minutes. Then, insoluble materials were removed from the reaction mixture by filtration through Celite. The solvent was carefully evaporated off the filtrate and the residual oil was distilled at 20 mmHg. The fraction which boiled at 60°-80° C. was collected to yield 4.04 g of (S)-tetrahydropyran-3-yl-carboxaldehyde which was contaminated with a trace amount of acetic acid and benzene as judged by 1 H-NMR.
NMR(CDCl 3 ): 1.45-1.91 (m, 4H), 2.34-2.43 (m, 1H), 3.47 (d.d.d., 1H, J=11.5, Hz), 3.63 (d.d.d., 1H, J=11.3, 6.5, 3.9 Hz), 3.72 (d.d., 1H, J=11.7, 6.8 Hz), 3.88 (d.d., 1H, J=11.7, 3.2 Hz), 9.62 (s, 1H).
PREPARATION M
(R)-Tetrahydropyran-3-yl -carboxaldehyde
Employing the procedures according to Preparation L, above, and starting with R-malic acid instead of S-malic acid affords (R)-tetrahydropyran-3-yl-carboxaldehyde. | 4y
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CROSS REFERENCE
[0001] The present application is a continuation of U.S. patent application Ser. No. 11/813,588 filed on Jul. 9, 2007 which is a §371 national phase of International Application No. PCT/GB2005/004972 filed Dec. 20, 2005.
BACKGROUND
[0002] This invention relates to wipes. The term “wipes” is used herein to refer to the kinds of disposable absorbent products known variously as tissues, cloths, paper towels, kitchen roll and the like, which may be made of paper, cloth or any other suitable material and which may be moist, wet or dry and which may be embossed, perforated, quilted or printed or have any other surface decoration or treatment.
[0003] Conventional products of this nature, and the dispensers in which they can be stored, are typically not very attractive to look at. Also it is often necessary to use two hands to extract the product from its dispenser. The present invention seeks to improve upon these existing products.
[0004] The invention provides a wipe comprising a generally flat piece of material in which said piece of material is formed into a non-planar form having a three-dimensional shape for storage in said shape.
[0005] The invention also provides a dispenser for storing a multiplicity of wipes, wherein the dispenser has a body which is adapted to suit the three-dimensional shape of the wipes.
[0006] The invention further provides a method of making wipes comprising the steps of producing a generally flat piece of material, forming the piece of material into a non-planar form having a three-dimensional shape and storing the piece of material in said shape.
DESCRIPTION OF THE DRAWINGS
[0007] By way of example, embodiments of the invention will now be described with reference to the accompanying drawings, in which:
[0008] FIGS. 1 a, 1 b and 1 c show a wipe according to the invention in its various stages of formation, and
[0009] FIGS. 2 , 3 and 4 show various forms of dispensers suitable for storing the wipes of FIG. 1 c.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] The wipe shown in the drawings is formed initially as a flat round disc 10 of material ( FIG. 1 a ). The wipe may comprise a single layer of material, or it may have two or more plies of the same or different materials. Here, the wipe has a laminated construction, with a lower layer 10 a of absorbent material, such as paper or the like, and an upper layer 10 b of impervious material, such as glacene paper. Each of the layers 10 a, 10 b may comprise one or more plies. The wipe may be impregnated, for example with a scent and/or possibly with an antibacteriological agent. The disc 10 may be formed by any suitable process, such as by being cut from a web of material produced in a continuous process on a machine.
[0011] As seen in FIGS. 1 a, 1 b and 1 c, the wipe is transformed from the planar form of disc 10 seen in FIG. 1 a into the three-dimensional form 11 seen in FIG. 1 c by tucking in a pleat 13 formed by two radial fold lines 14 , 15 in the disc 10 . The pleat 13 enables the disc 10 to be partially wrapped over itself, as seen in FIG. 1 b, which has the effect of drawing it into a conical configuration, as seen in FIG. 1 c.
[0012] By the nature of the material of which it is made, the wipe will tend to remain in its conical configuration once formed, and a number of wipes can thus be stacked one upon another in this configuration. There will be a tendency for the pleat 13 to protrude slightly from the wipe's conical profile, and this provides a useful provision by which a user can readily grasp a wipe from a stack. It will be noted that this can be done using only one hand. When a wipe is to be used to mop up a spillage of liquid on a kitchen top, for example, it can be lifted from a stack by its pleat 13 , carried to the spill and simply dropped onto it. When dropped, the wipe will tend to unwrap and return to its original planar form. This transformation will be assisted as the lower layer 10 a begins to absorb the liquid from the spill. When all the spilt liquid has been absorbed (or when the wipe has become saturated), the wipe can be lifted and disposed of In this process, the upper layer 10 b ensures that the user's hand does not become wet or soiled.
[0013] Various dispensers suitable for storing the wipes of FIG. 1 c are seen in FIGS. 2 , 3 and 4 . The dispenser of FIG. 2 comprises an essentially round hollow cylindrical body 16 with an internal diameter roughly equal to the overall diameter of the wipes when in their conical form of FIG. 1 c. A vertical slit 17 in the container body allows access to the pleat 13 of the uppermost wipe in the stack for grasping by a user.
[0014] The dispenser of FIG. 3 is in the nature of a free-standing support, with a base 18 , a stem 19 and a head 20 . The head 20 has a conical configuration to suit the conical configuration of the wipes, which sit upon it.
[0015] The dispenser of FIG. 4 is similar to that of FIG. 3 in that it has a conically-shaped head 20 on which the wipes are stacked. Here, however, the head 20 is attached by an elbow 21 to a bracket 22 which enables the dispenser to be mounted on a wall.
[0016] A stack of wipes stored and presented in the manner described above offers a more attractive solution for a kitchen than the more traditional forms of paper roller. The arrangement also facilitates use of the wipes, because they can be picked up with just one hand, unlike removing a tissue from a conventional roll of kitchen paper, which often requires two hands. Furthermore, the material and form of the wipe maximise its efficiency and ease of use.
[0017] It will be understood that the wipe may be formed initially in any suitable shape, not necessarily a geometric shape, and that it may also be formed into any suitable three-dimensional shape, again not necessarily a geometric one. | 4y
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to electrical generator but more particularly to a generator which optimizes the lifespan of a battery to extend its useful life.
[0003] 2. Background
[0004] Over the years a number of energy generators in the form of battery rechargers have been developed. Generally, they are directed towards electrically propelled vehicles.
[0005] U.S. Pat. No. 3,530,356 discloses a regenerator system for electric vehicles. The system includes an alternator ( 162 ) which produces alternating current voltage. A rectifier ( 164 ) may be included in the alternator in order to provide current for recharging batteries. A voltage regulator ( 172 ) operates as a safety device to prevent damage to the batteries by overcharging.
[0006] U.S. Pat. No. 3,972,380 presents a vehicle with regenerative power system. The vehicle includes a pair of alternators ( 44 ) serially connected to a regulator ( 68 ) in order to recharge batteries.
[0007] U.S. Pat. No. 4,082,988 describes an electric power plant for motor driven vehicles. The system presents motor/generator units ( 11 , 12 ), an AC capacitor ( 18 ) and a logic control and pulse generator unit ( 22 ).
[0008] U.S. Pat. No. 4,095,665 exposes an electric vehicle, in which a generator serves to charge the batteries that drive the motor when the vehicle is to be decelerated.
[0009] U.S. Pat. No. 4,099,589 discloses a DC electric car with auxiliary power and AC drive motor. The system offers an AC generator, a rectifier, a DC battery and an AC motor.
[0010] U.S. Pat. No. 4,222,450 presents an electrical drive for automobiles. The drive includes alternators ( 46 , 48 ), rechargeable batteries ( 50 , 52 ), voltage regulators ( 61 , 62 ) which are set to cause recharging at any given drop in battery voltage.
[0011] U.S. Pat. No. 4,254,843 describes an electrically powered vehicle. An engine/generator unit ( 66 , 98 ) is powered by a whirl ventilator system. The unit is started to charge the batteries when the level of charge therein has dropped below a predetermined level. The system includes a voltage regulating resistor ( 158 ) and transformer ( 142 ) for full wave rectification.
[0012] U.S. Pat. No. 4,298,082 discloses an electric propulsion system for wheeled vehicles. The system includes a generator ( 31 ) which is coupled by a diode ( 121 ) to the electrical circuit. A silicon controlled rectifier ( 124 ) is used to control excitation of the generator.
[0013] U.S. Pat. No. 4,300,088 presents an electric charging apparatus for ground vehicles. The apparatus includes alternators ( 2 , 4 , 51 ), stators (S 1 , S 2 ), rectifiers, a survoltage regulator and a voltage comparator.
[0014] U.S. Pat. No. 4,438,342 describes a novel hybrid electric vehicle, where the output of the alternator ( 34 ) goes through a semiconductor rectifier ( 40 ).
[0015] U.S. Pat. No. 4,477,764 exposes an energy and storage system for an electric vehicle. The system includes alternators ( 25 , 26 ) and charging internal diode rectifiers.
[0016] U.S. Pat. No. 4,597,463 discloses an electric vehicle. The system includes generators ( 48 , 82 , 78 , 34 ) linked to a voltage regulator ( 64 ), a DC to AC converter ( 52 ), a DC volt regulator ( 54 ), a chopper converter ( 56 ) and a transformer ( 60 ), all used to recharge batteries.
[0017] U.S. Pat. No. 6,333,620 presents a series type hybrid electric vehicle. The vehicle includes a generator ( 310 ), a generator controller ( 320 ) an insulated gate bipolar transistors.
[0018] U.S. Pat. No. 6,464,026 describes a control system for parallel hybrid vehicles. The system includes an electronic motor/generator ( 20 ), an inverter ( 24 ), a battery ( 22 ), a motor controller ( 42 ) and ammeters ( 66 , 67 ).
[0019] U.S. Pat. No. 6,476,509 finally discloses a mobile AC power system including an alternator ( 10 ) linked to a transformer ( 80 ), a circuit breaker ( 132 ), a frequency changer ( 82 ) and a voltage controller ( 138 ).
SUMMARY OF THE INVENTION
[0020] It is an object of this invention to provide for a battery recharger conceived for general purpose, including use on electrically propelled vehicles.
[0021] In order to do so, the generator uses transistors to increase the current flow in order to provide additional energy to be used as a power source as well as energy to recharge the battery.
[0022] The foregoing and other objects, features, and advantages of this invention will become more readily apparent from the following detailed description of a preferred embodiment with reference to the accompanying drawings, wherein the preferred embodiment of the invention is shown and described, by way of examples. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] [0023]FIG. 1 a The circuit in general with arrows pointing in the direction of the current coming from the battery and being used to power electric appliances.
[0024] [0024]FIG. 1 b Shows current going into the recharging circuit used for recharging the battery.
[0025] [0025]FIG. 2 Shows the part of the circuit containing the amplifying transistors.
[0026] [0026]FIG. 3 Shows the entire circuit generally.
[0027] [0027]FIG. 4 Is a schematic of the sequence.
[0028] [0028]FIG. 5 Shows the charging part of the circuit.
[0029] [0029]FIG. 6 Shows the energy generator in a residential environment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] [0030]FIG. 1 a An energy generator ( 10 ) consists of a main electronic circuit having circuit protection resistors ( 12 ), a voltage regulator circuit ( 14 ) to regulate the voltage as is known in the art, a transistor generating circuit ( 16 ) further described in FIG. 2, power on switch ( 20 ), power on light ( 22 ), charging light ( 24 ). A charging transformer ( 26 ) sends current through a diode with heat sink ( 28 ) further described in FIG. 5 as well as a battery recharging circuit ( 18 ), which recharges a battery ( 32 ), while a larger transformer ( 30 ) provides the AC output ( 34 ) that supplies power to appliances. The arrows indicate the direction of the current coming from the battery ( 32 ) and being used to power electric appliances. In FIG. 1 b The same circuit shows arrows pointing the direction of the current that goes into the battery recharging circuit ( 18 ), used for recharging the battery ( 32 ).
[0031] [0031]FIG. 2 The transistor circuit ( 16 ) consists of two banks of transistors ( 34 ) each comprised of a plurality of transistors and a series of redundant IC circuits ( 36 ) which are repeated several times as can be seen in FIG. 3 where there are five redundant IC circuits ( 36 ) followed by 5 more complex IC circuits ( 38 ) wherein current amplification occurs.
[0032] [0032]FIG. 4 Power from the battery ( 32 ), after having been converted from DC to AC goes through the larger transformer ( 30 ) which brings its voltage to the range of 110-220 VAC. Power is then passed through the voltage regulator circuit ( 14 ) before being released through the AC output ( 34 ) as well as onto the charging transformer ( 26 ), the battery recharging circuit ( 18 ) and then the diode with heat sink ( 28 ) . Power from the battery is also passed through the transistor generating circuit ( 16 ) which then goes into the battery recharging circuit ( 18 ).
[0033] [0033]FIG. 5 Shows the charging circuit ( 28 ) with its diodes ( 40 ) and heat sink ( 42 ) which is connected to the output of the circuit to turn DC into AC ( 14 ).
[0034] [0034]FIG. 6 In a household environment ( 44 ), the energy generator ( 10 ) is independent from the main circuit breaker ( 46 ) and provides power in case of a power outage by having a plug ( 50 ) connected into at least one outlet ( 52 ) which then runs through to other outlets ( 52 ) in order to provide power to a household electrical circuit. The energy generator ( 10 ) can also be used on an electric vehicle. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for adjusting an angle of a display means, and more particularly to an apparatus for adjusting an angle of a display means, which easily controls the view angle of the display so as to comply with a user's wishes, and a connection bracket of the apparatus.
2. Description of the Related Art
Typically, thin-type display means such as Liquid Crystal Display (LCD) TVs or Plasma Display Panel (PDP) TVs are fixed to a wall, i.e., in a built-in mode, thereby maximizing space utilization. This built-in mode does not generate an unnecessary gap between the back surface of the display means and the wall, thereby improving installation efficiency.
However, with this built-in type display means, in case the user wants to adjust a view angle of the display means fixed to the wall, the display means must be entirely detached from the wall. Then, after adjusting the view angle of the display means, the display means must be again attached to the wall. Therefore, this procedure is very inconvenient to the user as well as causes damage to the wall.
Therefore, in order to solve the aforementioned problems, various apparatuses for supporting the thin-type display means so as to adjust the view angle of the display means have been developed.
FIG. 1 is a perspective view of a conventional apparatus for adjusting an angle of a wall-mounted display means.
With reference to FIG. 1 the conventional apparatus for adjusting the angle of the wall-mounted display means comprises a fixture 31 , a pair of supporters 32 , and link members 33 . The fixture 31 is attached to a wall. One end of each supporter 32 is pivotably connected to the fixture 31 . The link members 33 serve to connect the supporters 32 to the fixture 31 .
A thin-type display means D is interposed between two supporters 32 , thereby being installed on the conventional apparatus for adjusting the angle of the display means. The supporters 32 provided with the display means D are spread or folded, thereby adjusting the view angle of the display means D.
Herein, an angle of spreading or folding the supporter 32 is restricted by the link member 33 , which moves along the supporter 32 .
According to the above-described link system supporting apparatus, the view angle of the display means D is adjusted by spreading and folding the supporters 32 . Then, the adjusted angle of the display means D is fixed by the link members 33 .
However, since the display means D is very heavy, women or old and feeble persons cannot easily adjust the view angle of the display means D using the above-described link system supporting apparatus.
Although the view angle of the display means D is adjusted, it is not easy to finely adjust the view angle of the display means D as to comply with the user's wishes.
SUMMARY OF THE INVENTION
Therefore, the present invention has been made in view of the above problems, and it is an object of the present invention to provide an apparatus for adjusting an angle of a display means, which easily controls the view angle of the display means by the manipulation of a side hand lever so as to comply with a user's wishes.
It is another object of the present invention to provide a connection bracket for easily attaching and detaching the angle adjusting apparatus to and from a display means.
In accordance with one aspect of the present invention, the above and other objects can be accomplished by the provision of an apparatus for adjusting an angle of a display means, comprising: a fixing bracket fixed to a wall or a supporter; two guide brackets, each being installed on both ends of the fixing bracket; connection brackets, one end of each connection bracket being pivotably connected to one end of the guide bracket and one surface of each connection bracket is connected to a designated surface of a display means; a flap-fixing bracket being attached to a designated area of the fixing bracket; a flap comprising two pieces crossing each other, one end of one piece of the flap being fixed to the flap-fixing bracket and one end of the other piece of the flap being pivotably connected to the flap-fixing bracket; a balance shaft for adjusting a angle of the connection bracket according to the spreading and folding of the flap, each of both ends of the balance shaft being connected to respective connection brackets, and the other end of one piece of the flap being fixed to the balance shaft and the other end of the other piece of the flap is connected to the balance shaft so as to move along the balance shaft; and an angle adjustable shaft being connected to one end of one piece of the flap and including means for adjusting the spreading and folding of the flap.
In accordance with another aspect of the present invention, there is provided a connection bracket comprising a product bracket including means for being fixed to one surface of the display means and means for being fixed to a holding-down bracket; and a holding-down bracket including means for being easily attached to and separated from the product bracket.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of a conventional apparatus for adjusting an angle of a display means;
FIG. 2 is a perspective view of an apparatus for adjusting an angle of a display means in accordance with the present invention;
FIG. 3 is an exploded perspective view of the apparatus for adjusting the angle of the display means in accordance with the present invention;
FIG. 4 is a side view of the apparatus for adjusting the angle of the display means in accordance with the present invention;
FIG. 5 is a schematic view showing the connection between a display means and connection brackets of the apparatus for adjusting the angle of the display means in accordance with the present invention;
FIG. 6 is a schematic view showing the connection between the connection brackets and the apparatus for adjusting the angle of the display means in accordance with the present invention; and
FIG. 7 is a schematic view showing the separation of the display means from the apparatus for adjusting the angle of the display means in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.
FIG. 2 is a perspective view of an apparatus for adjusting a angle of a display means in accordance with the present invention.
With reference to FIG. 2 , the apparatus for adjusting the angle of the display means of the present invention comprises a fixing bracket 1 , two guide brackets 2 , connection brackets 40 , a flap-fixing bracket 13 , a flap 16 , a balance shaft 15 , and an angle adjustable shaft 11 . The fixing bracket 1 is fixed to a wall or a supporter. Each guide bracket 2 is installed on both ends of the fixing bracket 1 . One end of the connection bracket 40 is pivotably connected to one end of the guide bracket 2 , and the other end of the connection bracket 40 is connected to a designated surface of a display means. The flap-fixing bracket 13 is attached to a designated area of the fixing bracket 1 . The flap 16 comprises two pieces crossing each other. One end of one piece of the flap 16 is fixed to the flap-fixing bracket 13 and one end of the other piece of the flap 16 is pivotably connected to the flap-fixing bracket 13 . Both ends of the balance shaft 15 are connected to each connection bracket 40 . The other end of one piece of the flap 16 is fixed to the balance shaft 15 , and the other end of the other piece of the flap 16 is connected to the balance shaft 15 50 as to move along the balance shaft 15 . The balance shaft 15 serves to adjust the angle of the connection bracket 40 according to the spreading and folding of the flap 16 . One end of the flap 16 is connected to the angle adjustable shaft 11 . The angle adjustable shaft 11 includes a means for modulating the spreading and folding of the flap 16 .
In more detail, the fixing bracket 1 includes a plurality of holes, thereby being fixed to the wall or the supporter using screws, or bolts and nuts.
The guide brackets 2 and the flap-fixing bracket 13 are fixed to the fixing bracket 1 .
A hinge hole is formed on one end of the guide bracket 2 , thereby coupling the guide bracket 2 with the corresponding connection bracket 40 by a hinge pin 6 inserted into the hinge hole.
A link bracket 4 is connected to the guide bracket 2 by a connection pin 3 . The link bracket 4 serves to spread the connection bracket 40 within a designated angle range and to support the connection bracket 40 .
A U-groove is formed on both side surfaces of the guide bracket 2 , thereby easily folding the connection bracket 40 into the guide bracket 2 .
Preferably, a through hole 3 a for moving the link bracket 4 according to the modulation of the angle of the connection bracket 40 is formed on both side surfaces of the guide bracket 2 .
Further, in order to fix and rotate the angle adjustable shaft 11 , a hole or a groove is formed on both side surfaces of the guide bracket 2 .
Preferably, the connection bracket 40 comprises a product bracket 20 , which is connected to a designated surface of the display means and includes a buckle 21 , and a holding-down bracket 9 with a fixing stopper 10 . Elasticity of an elastic means is applied to the fixing stopper 10 .
Herein, the elastic means may be a spring.
The product bracket 20 comprises a plurality of screw holes 22 , which are connected to the display means using screws, and the buckle 21 , which is engaged with the fixing stopper 10 of the holding-down bracket 9 .
One end of the product bracket 20 is bent, thereby hanging the product bracket 20 on the holding-down bracket 9 . The other end of the product bracket 20 is fixed to the fixing stopper 10 of the holding-down bracket 9 .
Alternatively, the product bracket 20 and the holding-down bracket 9 may be integrally formed to form the connection bracket 40 .
The connection bracket 40 is connected to the corresponding link bracket 4 by a stationary pin 5 .
The connection bracket 40 is connected to the balance shaft 15 .
The flap-fixing bracket 13 is attached to a designated area of the fixing bracket 1 and comprises a groove for easily folding the flap 16 .
A stationary bracket 18 for supporting the angle adjustable shaft 11 is connected to the flap-fixing bracket 13 by an shaft fixing pin 13 b.
A sliding hole 13 a is formed on both side surfaces of the flap-fixing bracket 13 . The sliding hole 13 a serves to move the shifting boss 17 . The shifting boss 17 moves along a screw thread 11 b formed on the outer surface of one end of the angle adjustable shaft 11 .
One end of one piece of the flap 16 is connected to the shifting boss 17 and one end of the other piece of the flap 16 is fixed to the flap-fixing bracket 13 by the shaft fixing pin 13 b . Two pieces of the flap 16 cross each other on a connection pin 19 .
The other end of one piece of the flap 16 is fixed to the balance shaft 15 by an shaft fixing pin 15 a , and the other end of the other piece of the flap 16 is connected to a sliding bracket 14 so as to move along the balance shaft 15 .
Preferably, two pieces of the flap 16 may be spread and folded centering on a X-shaped crossing point.
The balance shaft 15 is connected to the flap 16 by the shaft fixing pin 15 a and the sliding bracket 14 . Both ends of the balance shaft 15 are combined with each holding-down bracket 9 .
The screw thread 11 b is formed on the outer surface of one end of the angle adjustable shaft 11 . The other end of the angle adjustable shaft 11 is connected to an angle adjustable extension shaft 11 a for easily adjusting the angle of the connection bracket 40 .
Preferably, in order to easily rotate the angle adjustable shaft 11 , the other end of the angle adjustable shaft 11 is connected to an angle adjustable extension shaft 11 a by a universal joint.
Further, preferably, an angle adjustable hand lever 12 for easily rotating the angle adjustable shaft 11 is formed on one end of the angle adjustable extension shaft 11 a.
FIG. 3 is an exploded perspective view of the apparatus for adjusting the angle of the display means in accordance with the present invention.
With reference to FIGS. 2 and 3 , both ends of the fixing bracket 1 are respectively connected to each of a pair of the guide brackets 2 .
The through hole 3 a for moving the link bracket 4 and other plural holes are formed on the guide bracket 2 . Further, the hinge hole for inserting the hinge pin is formed on one end of the guide bracket 2 .
As described above, the connection bracket 40 comprises the product bracket 20 and the holding-down bracket 9 .
The holding-down bracket 9 is connected to the link bracket 4 and comprises the fixing stopper 10 and a spring 10 a.
1 n order to be firmly combined with the product bracket 20 , a plurality of holes are formed on the holding-down bracket 9 .
The product bracket 20 comprises a plurality of the screw holes 22 , which are connected to the display means by screws, and the buckle 21 , which is engaged with the fixing stopper 10 of the holding-down bracket 9 .
The stationary bracket 18 for inserting and fixing the angle adjustable shaft 11 is connected to the flap-fixing bracket 13 . The sliding hole 13 a is formed on both side surfaces of the flap-fixing bracket 13 .
FIG. 4 is a side view of the apparatus for adjusting the angle of the display means in accordance with the present invention.
With reference FIGS. 2 , 3 , and 4 , the operation of the apparatus for adjusting the angle of the display means in accordance with the present invention is described in detail.
The connection bracket 40 comprises the product bracket 20 and the holding-down bracket 9 . The product bracket 20 comprises a means for being connected to the display means and a means for being fixed to the holding-down bracket 9 . The holding-down bracket 9 comprises a means for being easily connected to and separated from the product bracket 20 .
The above-described connection bracket 40 can be easily connected to and separated from the display means. Therefore, the connection bracket 40 may be used in an apparatus for simply fixing the display means as well as an apparatus for adjusting the angle of the display means.
The product brackets 20 screw-jointed with the display means are coupled to the corresponding holding-down brackets 9 , thereby fixing the display means to the connection brackets 40 .
The angle adjustable shaft 11 connected to the angle adjustable hand lever 12 by the angle adjustable extension shaft 11 a is rotated by turning the angle adjustable hand lever 12 in the clockwise direction.
The shifting boss 17 , in which the angle adjustable shaft 11 with the screw thread 11 b is inserted, is pulled along the screw thread 11 b , and the flap 16 connected to the shifting boss 17 is spread centering on the connection pin 19 of the crossing point.
When the flap 16 is spread, the sliding bracket 14 connected to the flap 16 is pulled, and the holding-down bracket 9 connected to the balance shaft 15 is guided by the link bracket 4 and spread from the guide bracket 2 .
Therefore, the display means is caused to lean forward.
After adjusting the angle of the display means, the angle adjustable extension shaft 11 a is put aside so as to desirably view the display means.
On the other hand, the angle adjustable shaft 11 connected to the angle adjustable hand lever 12 by the angle adjustable extension shaft 11 a is reversibly rotated by turning the angle adjustable hand lever 12 in the counter clockwise direction. Then, the shifting boss 17 , in which the angle adjustable shaft 11 with the screw thread 11 b is inserted, is pushed along the screw thread 11 b , and the flap 16 connected to the shifting boss 17 is folded centering on the connection pin 19 of the crossing point.
When the flap 16 is folded, the sliding bracket 14 connected to the flap 16 is pushed into the shaft fixing pin 15 a of the balance shaft 15 , and the holding-down bracket 9 connected to the balance shaft 15 is guided by the link bracket 4 and folded into the guide bracket 2 .
Therefore, the angle of the display means is reduced and the display means is caused to stand vertically straight.
FIG. 5 is a schematic view showing the connection between the display means and the product bracket 20 of the apparatus for adjusting the angle of the display means in accordance with the present invention.
With reference to FIG. 5 , holes for screw-jointing are formed on the back surface of the display means.
One end of the product bracket 20 is bent, thereby being firmly coupled with the holding-down bracket 9 . The product bracket 20 comprises a plurality of the screw holes 22 for being screw-jointed with the display means.
Further, the product bracket 20 comprises the buckle 21 to enable it to be hung on and fixed to the fixing stopper 10 of the holding-down bracket 9 .
As shown in FIG. 5 , the connection between the display means and the product bracket 20 is accomplished by connecting screws to the holes of the back surface of the display means and to the screw holes 22 of the product bracket 20 .
FIG. 6 is a schematic view showing the connection between the connection brackets 40 and the apparatus for adjusting the angle of the display means in accordance with the present invention.
With reference to FIG. 6 , the product brackets 20 screw-connected to the display means are coupled with the corresponding holding-down brackets 9 .
Herein, the bending portion of the product bracket 20 is inserted into the groove of the holding-down bracket 9 in the direction of a.
Then, when the display means is pushed in the direction of b, the buckle 21 of the product bracket 20 is engaged with the fixing stopper 10 via the hole of the holding-down bracket 9 .
Elasticity of the spring 10 a is applied to the fixing stopper 10 . When the buckle 21 pushes the fixing stopper 10 , the spring 10 a expands and the fixing stopper 10 moves downward.
When the buckle 21 is entirely inserted into the fixing stopper 10 , the fixing stopper 10 is again pulled by the elasticity of the spring 10 a.
Thereby, the product bracket 20 is coupled with the holding-down bracket 9 .
FIG. 7 is a schematic view showing the separation of the display means from the apparatus for adjusting the angle of the display means in accordance with the present invention.
With reference to FIG. 7 , when the holding-down bracket 9 pulls the fixing stopper 10 in the direction of c, the spring 10 a expands and the buckle 21 is disengaged from the fixing stopper 10 .
Then, when the display means (not shown) is pulled in the direction of d, the lower surface of the product bracket 20 is separated from the holding-down bracket 9 .
The display means (not shown) is elevated in the direction of e. Then, the bending portion of the product bracket 20 is separated from the holding-down bracket 9 , thereby entirely separation the display means from the holding-down bracket 9 .
The above-described connection bracket 40 is easily attachable and detachable, thereby being very simply installed on the apparatus for adjusting the angle of the display means.
As apparent from the above description, the present invention provides and apparatus for adjusting a angle of a display means, in which women or old and feeble persons can easily adjust the view angle of the display means by turning the hand lever.
Further, with the apparatus for a adjusting the angle of the display means of the present invention, a desirable view angle of the display means can be finely adjusted.
After adjusting the view angle of the display means, the hand lever can be placed behind of the apparatus, thereby keeping its appearance clean.
A motor and a module for controlling the motor may be used, thereby automatically rotating the angle adjustable shaft without manipulation of the angle adjustable hand lever.
Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | 4y
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to German Patent Application No. 102008007692.9, filed Feb. 6, 2008, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The present invention relates to an external gear shift for the gear selection in a manual transmission comprising a gearshift/selector lever and a sensing element for detecting the position of the gearshift/selector lever. Such an external gear shift generally forms the user interface of a shift-by-wire shifting device, in which a control circuit triggers by reference to the detected position of the gearshift/selector lever.
BACKGROUND
A manual transmission conventionally has a shift rail which is movable in two degrees of freedom. Due to a movement in one of these degrees of freedom, the shift rail is brought into engagement with one or more synchronizing devices required to engage a gear and due to the movement in the other degree of freedom, this drives an adjusting movement of the respectively selected synchronizing device. These movements must substantially take place successively since the engagement of the shift rail must be made before its adjusting movement can be driven. In order to assist the driver during shifting and to ensure that selection and shifting movements are executed correctly one after the other, mechanical shifting devices conventionally have a link, in which a gearshift/selector lever coupled to the shift rail of the transmission is guided in shifting and selecting tracks which are orthogonal to one another. There are shift-by-wire shifting devices, which also use a gearshift/selector lever which is movably guided in a link in two degrees of freedom and which control the shift rail proportionally to the movement of the gearshift/selector lever in order to offer the driver the handling to which he is accustomed from mechanical gear shifts.
While in a mechanical shifting device, the driver may experience a resistance of the transmission to an unmatched shifting movement and can match the track along which he guides the gearshift/selector lever to this resistance, this is not possible in a shift-by-wire shifting device. In order to reliably eliminate a shifting movement which the transmission cannot follow, the link guiding the gearshift/selector lever must therefore have a narrow tolerance in a shift-by-wire shifting device. This makes a shifting process with track change laborious for the driver since the gearshift/selector lever cannot be moved in one stroke from one gear position into the other gear position but must be halted on the way twice at precisely the correct position to change the direction of movement.
In view of the foregoing, it is at least one object of the invention to provide an external gear shift for a shift-by-wire shifting device with a link-guided gearshift/selector lever, which allows rapid, convenient shifting. In addition, other objects, desirable features and characteristics will become apparent from the subsequent summary and detailed description, and the appended claims, taken in conjunction with the accompanying drawings and this background.
SUMMARY
This at least one object, other objects, desirable features and characteristics, are achieved by an external gear shift for the gear selection in a manual transmission comprising a gearshift/selector lever, which is guided in a link plate and which is movable along a selector track and a plurality of shifting tracks, and a measuring sensor to detect an instantaneous position of the gearshift/selector lever, in which guide fingers of the link plate disposed between shifting and selector tracks each have flanks oriented obliquely to the shifting and selector tracks.
Due to the obliquely oriented flanks, during the movement of the gearshift/selector lever in shifting movements with a track change in the area of the selector track, the movement can be transferred continuously from one selector track into the next so that any interruption of the movement transverse to the direction of the selector tracks can be avoided. The shape and position of the oblique flanks are expediently selected in such a manner that it is possible for the driver to make a rapid movement of the gearshift/selector lever, especially with a track change. The embodiments of invention are based on the knowledge that the shifting link can have a very large tolerance and can be optimized to a rapid movement of the gearshift/selector lever, if the basic principle of proportional control is broken and not every movement which the gearshift/selector lever can execute, is converted into a proportional movement of the shift rail. It is therefore not necessary for every position that the gearshift/selector lever can occupy on one of the sloping flanks to correspond to a possible position of the shift rail during proportional control of the shift rail; the task of guiding the shift rail on a previously known path having a sufficiently narrow tolerance for reliable shifting can be left to the control circuit.
The guide fingers are preferably provided with the oblique flanks on respectively only one side so that frequent shifting movements, for example, shifting to a next-higher or next-lower gear can be facilitated but unusual shifting movements which could correspond to undesirable shifting processes such as skipping over several gears, are made more difficult.
In particular, if two guide fingers disposed oppositely between two identical shifting tracks have oblique flanks on opposite sides, the shifting movement during a track change can be configured to be particularly comfortable and reliable in operation.
For a continuous movement of the gearshift/selector lever from one shifting track to an adjacent one, it is furthermore advantageous if the oblique flanks of the oppositely arranged guide fingers are disposed parallel to one another.
In particular, if the distance between tangents of the oblique flanks at least corresponds to a thickness of the gearshift/selector lever, the gearshift/selector lever can cross the selector track without needing to change its direction of movement.
With regard to the movement sequence of the shifting movement, it is furthermore advantageous if a tangent of one oblique edge extends at an angle between about 10 and 60 degrees to an edge of an adjoining shifting track. If the angle lies outside this range, the profile of the tangent is in each case too similar to the edge of a conventional shifting track or selector track to appreciably facilitate and accelerate the shifting movement.
In this case, particular advantages are achieved if the angle between the tangent of an oblique flank and the edge of the adjacent shifting track increases toward the selector track. Since the degree of inclination varies, an optimal shifting path can be achieved, for example, by means of a plurality of successive oblique sections, in which both the track changing movement and also the transition from or into the movement along the shifting tracks can be supported in an exceptional manner.
In addition, in an area of a guide finger facing away from the selector track, a straight section is preferably followed by an oblique flank so that very exact guidance of the gearshift/selector lever in an end area of the shifting track is achieved.
In this case, it is preferable if the length of the straight section is between about 25 and 30 percent of the shifting distance, the shifting distance being defined by the path of the gearshift/selector lever between a position in an engaged gear and a position in the selector track.
In addition, additional advantages are obtained for the external gear shift if one shifting track which is adjacent to a shifting track of a reverse gear has no oblique flank on a side facing the reverse gear. Thus, any undesirable movement of the gearshift/selector lever into the shifting track of the reverse gear can be made more difficult so that reverse gear can only be engaged with a shifting movement which is executed exactly during the track change.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and:
FIG. 1 shows a schematic diagram of a shift-by-wire shifting device, which uses an external gear shift according to an embodiment of the invention;
FIG. 2 shows a shifting link, in which a gearshift/selector lever is movable, according to a first embodiment of the invention;
FIG. 3 shows the shifting link from FIG. 2 in another advantageous embodiment; and
FIG. 4 shows the shifting link from FIG. 2 in a third advantageous embodiment.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit application and uses. Furthermore, there is no intention to be bound by any theory presented in the preceding background and summary or the following detailed description.
The shifting device shown schematically in FIG. 1 comprises an external gear shift with a gearshift/selector lever 1 , which projects into the passenger compartment of an automobile and is guided in a link plate 2 , and a sensor 3 for detecting the position of the gearshift/selector lever 1 , which is movable in the direction of a selector track 4 cut out in the link plate 2 and in the direction of shifting tracks 5 which cross the selector track 4 . The sensor 3 delivers coordinate values s, w of the gearshift/selector lever 1 with respect to these two directions to an electronic control circuit 6 . Connected to the control circuit 6 is an actuator device with two degrees of freedom, shown here as two individual adjusting cylinders 7 , 8 . The adjusting cylinders 7 , 8 drive a shifting movement in two degrees of freedom, such as possibly an axial displacement and a rotation, of a shift rail of a stepped transmission, which is not shown but is known per se.
As long as the gearshift/selector lever 1 is located in one of the tracks 4 or 5 , the control circuit 6 specifies a desired position of the adjusting cylinder 7 for the shifting movement with reference to the coordinate s of the gearshift/selector lever 1 delivered by the sensor 3 in the shifting track direction, regardless of the selector track coordinate w, and a desired position of the adjusting cylinder 8 with reference to the selector track coordinate w and regardless of the shifting track coordinates. The rectilinearly elongated shifting and selector tracks 4 , 5 are dimensioned in such a manner that each position that the gearshift/selector lever 1 can adopt in the shifting or selector tracks is mapped by the control circuit 6 onto a position of the adjusting cylinders 7 , 8 .
FIG. 2 shows an enlarged plan view of the link plate 2 . The specific shifting track for gears 1 and 2 is designated hereinafter by 1 - 2 , the shifting track for gears 3 and 4 is designated by 3 - 4 , and the shifting track for gears 5 and 6 is designated by 5 - 6 . The positions of the gearshift/selector lever 1 at the respective end of the shifting tracks corresponding to the engaged gear are depicted by the dashed lines 13 in the diagram. A central line 14 representing a position of the gearshift/selector lever 1 in the selector track 4 is also shown by a dashed line.
A guide finger 9 is disposed between each two neighboring shifting tracks 5 on the link plate 2 on both sides of the selector track 4 . Adjacent to the points of intersection of the selector and shifting tracks 4 , 5 , triangular sections are recessed from the link plate 2 so that the guide fingers 9 have an oblique flank 10 on one of their longitudinal sides in each case.
Two guide fingers located opposite one another between two identical shifting tracks 5 on both sides of the selector track 4 are provided with the oblique flanks 10 on respectively opposite longitudinal sides. The flanks 10 of these opposite fingers 9 are parallel to one another and the distance between the parallels formed by the two oblique flanks 10 corresponds at least to the thickness of a stick of the gearshift/selector lever 1 projecting through the link plate 2 , so that the gearshift/selector lever 1 can be moved along the two oblique flanks 10 without a change of direction.
An angle α formed by the flanks 10 with an edge of an adjoining shifting track should be smaller than about 60° so as not to force an unnecessarily abrupt change in direction of the gearshift/selector lever 1 on changing from one shifting track 5 to the next. The slopes do not extend right into an outer section 15 of the shifting tracks 5 so that at the beginning of a shifting movement, the gearshift/selector lever 1 is always guided there in the direction of the opposite switching position of the same shifting track. The outer section 15 extends over about 25 to 30 percent of a shifting distance, which is defined by the distance between the end positions of the gearshift/selector lever 1 in the shifting tracks 5 marked by the line 13 from the central line 14 of the selector track 4 . The angle α is therefore generally not less than about 10°.
In contrast to the shifting fingers 9 between the shifting tracks of the forward gears, a guide finger 9 ′ formed between the shifting track 1 - 2 and a shifting track 5 ′ for the reverse gear R disposed adjacent to this has no slope in order to avoid accidental shifting into reverse gear.
The diagram further shows a profile of a shifting movement of the gearshift/selector lever 1 corresponding to an upward shift into a next higher gear. The gearshift/selector lever 1 is initially located in a position at a lower end of the shifting track 1 - 2 , which corresponds to second gear being engaged. As is indicated by the dot-dash line, a shifting movement in the direction of the upper end of the shifting track 3 - 4 is executed along the two guide fingers 9 between the shifting tracks 1 - 2 and 3 - 4 , the oblique flanks 10 appreciably facilitating the movement since the gearshift/selector lever 1 crosses the selector track 4 without any abrupt change of direction.
In FIG. 3 , the link plate 2 explained in FIG. 2 is shown in another advantageous embodiment of the invention. In this case, the oblique flanks 10 of the guide fingers 9 comprise a plurality of sections of different slope, wherein the tangent 11 of a first section of the oblique flank 10 facing the selector track 4 with the line 12 representing the edge of the shifting track 5 - 6 , encloses a larger angle than a tangent 11 ′ of a second section of the oblique flank 10 facing away from the selector track 4 . This form of the oblique flanks 10 supports a flowing shifting movement with change in track, as is again depicted by the dash-dot line, in an improved manner compared with the arrangement shown in FIG. 2 .
If, in an advantageous further development of the invention, the oblique flanks 10 are each divided into a plurality of sections having different inclinations, and the angles formed in each case by the tangents of the sections 11 , 11 ′ etc. with the edge of the shifting track 5 increase toward the selector track 4 , the arrangement shown in FIG. 4 is obtained, which optimizes the shifting movements with a track change with regard to their profile.
In this case, the beveled flanks 10 are configured as a rounding, and in each case, by means of the rounding of the flank 10 , an end of the guide fingers 9 facing the selector track 4 goes over continuously into the straight section 15 of the guide fingers 9 at the end of the shifting track 5 .
While at least one exemplary embodiment has been presented in the foregoing summary and detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration o in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims and their legal equivalents. | 4y
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is related to a door lock with a clutch having a cam-styled axle sleeve, and especially to providing a cam-styled axle sleeve on a rotation axle of an outer lock part. By controlling whether the cam-styled axle sleeve is connected with a rotation axle of an inner lock part with a control device, the effect of opening and closing of the door lock is controlled, which particularly suits the lock structures of a gate, a room door etc.
[0003] 2. Description of the Prior Art
[0004] Conventional lock structures are mainly mounted on door panels with an inner and an outer side, such a door lock is generally comprised of a dead bolt, two fixing seats, a restoring mechanism with a torsional spring in a receiving chamber, a restoration mechanism to move back a linking-up column by means of a torsion spring, a connecting mechanism to fix the two fixing seats on the door panel, and two handles respectively on the two fixing seats to be linked up with a control rod. Such a door lock structure needs multiple operating steps to open the lock indoors, and will delay the time for fleeing from danger; thereby it is not an ideal device.
[0005] The inventor of the present invention develops a novel door lock with a clutch having a cam-styled axle sleeve, which can be easily opened indoors, and can be opened outdoors electrically or manually.
SUMMARY OF THE INVENTION
[0006] The main object of the present invention is to provide a door lock with a clutch having a cam-styled axle sleeve. By controlling the cam-styled axle sleeve through an outer lock part provided with a control device, the cam-styled axle sleeve moves forwards to connect with a second rotation axle of an inner lock part to control opening and closing of the door lock.
[0007] The secondary object of the present invention is to provide a door lock with a clutch having a cam-styled axle sleeve, wherein through the inner lock part, the door can be opened indoors any time by directly pressing down the inner handle on the door, especially favor fleeing from danger in an emergency.
[0008] To achieve the objects stated above, the present invention is comprised mainly of an inner lock part and an outer lock part integrated with each other, and are further combined with a dead bolt and a telescopic spring-loaded latch bolt mounted on a lateral side of a door panel. The outer lock part is mounted on the outer side of a door panel, and the inner lock part on the inner side; both the housings of the inner and the outer lock parts are provided with a handle to drive the internal rotation axle thereof. The rotation axle of the outer lock part is provided thereon with a cam-styled axle sleeve which is controlled for forwarding or positioning by another element of the outer lock part a control device; the rotation axle of the inner lock part can drive an inner pull rod, where the remote end connects another axle of the inner lock part and is linked up with the dead bolt. The front end of the rotation axle of the inner lock part is further connected with a second rotation axle in addition to being linked up with the latch bolt. The second rotation axle can be telescopically connected with the cam-styled axle sleeve of the rotation axle of the outer lock part to make integration of the rotation axle of the outer lock part with the rotation axle of the inner lock part. By rotation of the handles to control extending and contracting of the dead bolt and the latch bolt on the door; the door is opened by pressing down the handle of the inner lock part or the outer lock part. When the cam-styled axle sleeve of the outer lock part is controlled and positioned by the control device, the rotation axle of the outer lock part and that of the inner lock part are separated, therefore the dead bolt and the latch bolt on the door are not influenced by the revolving direction or prizing of the handle of the outer lock part. By virtue that the rotation axle of the inner lock part can be linked up with the dead bolt and the latch bolt, so that in any state, rotation of the handle of the inner lock part can control extending and contracting of the dead bolt and the latch bolt on the door. And the control device can allow the lock to control displacement of the cam-styled axle sleeve of the outer lock part manually, or automatically by providing with an electric circuit board, a motor and a gear etc. to cooperate with an externally connected card reader, a code reader, a remote control etc. to open the lock in a more convenient and safer way.
[0009] The present invention will be apparent in its features and specific structure after reading the detailed description of the preferred embodiment thereof in reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a perspective view of an embodiment of the present invention connecting with a door panel;
[0011] [0011]FIG. 2 is an analytic perspective view showing the elements of an outer lock part of the embodiment of the present invention;
[0012] [0012]FIG. 3 is an analytic perspective view showing the elements of a control device of the embodiment of the present invention;
[0013] [0013]FIG. 4 is an analytic perspective view showing the elements of an inner lock part of the embodiment of the present invention;
[0014] [0014]FIG. 5 is a sectional view of the embodiment of the present invention after assembling;
[0015] [0015]FIG. 5 a is a schematic sectional view showing invalidation of operation of the outer lock part of the present invention;
[0016] [0016]FIG. 5 b is a partially enlarged schematic view of the outer lock part of the present invention;
[0017] [0017]FIG. 5 c is a schematic sectional side view of the outer lock part of the present invention;
[0018] [0018]FIG. 6 is a schematic sectional view showing effectiveness of operation of the outer lock part of the present invention;
[0019] [0019]FIG. 6 a is a partially enlarged schematic view of the outer lock part of the present invention;
[0020] [0020]FIG. 6 b is a schematic sectional side view of the outer lock part of the present invention;
[0021] [0021]FIG. 7 is a schematic view showing opening of the door in using the inner lock part of the present invention;
[0022] [0022]FIG. 8 is a schematic view showing closing of the door in using the inner lock part of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring to FIG. 1, the door lock with a clutch having a cam-styled axle sleeve of the present invention is comprised of an outer lock part 10 , an inner lock part 40 , a dead bolt 60 and a spring-loaded latch bolt 70 mounted together on a door panel 80 .
[0024] Wherein: referring to FIG. 2, the outer lock part 10 is a housing with a suitable size, and is provided at suitable locations therein with screw studs and protruding blocks for screwing connecting and positioning of the remaining members. The outer lock part 10 is provided on the housing surface thereof with a handle 11 for rotating an inner rotation axle 13 ; when the rotation axle 13 is connected with the handle 11 , a spring 12 is provided between them for restoration of the handle 11 . The front and the rear portions of the rotation axle 13 are square stubs with different perimeters; a pot-like member 131 flares out from the step like surface between the front and the rear portions; the pot-like member 131 is provided thereon with a positioning notch 132 ; the front square stub with a smaller perimeter is provided on the end face thereof with a protruding post 133 ; a spring 14 and a cam-styled axle sleeve 15 are slipped over the front square stub. The axle hole 17 of the cam-styled axle sleeve 15 is a through hole; the cam-styled axle sleeve 15 is provided at the middle section thereof externally with an engaging edge 16 to be engaged and controlled by a control device 20 provided above the rotation axle 13 .
[0025] The control device 20 (referring to FIG. 3) is comprised of: a motor 21 , a gear 25 , an abutting block 27 , a pull rod 30 and a lid 23 . Wherein the axle of the motor 21 is in the form of a screw rod 22 to be engaged with the gear 25 ; the gear 25 is provided on one side thereof with a recess for positioning a protruding block provided on the housing and is provided on the other side with an eccentric protruding block 26 for placing in a recess 28 on the abutting block 27 . The abutting block 27 is provided on the top thereof with a positioning groove 29 for positioning of the pull rod 30 (on the abutting block 27 ) having on one end thereof a sheet 32 , on the other end thereof a positioning block 31 and being slipped thereover by a spring 33 . And the lid 23 with a pair of positioning bars 24 is locked in the housing. The abutting block 27 is provided on the top thereof with a positioning groove 29 for positioning of the pull rod 30 (on the abutting block 27 ) having on one end thereof a sheet 32 , on the other end thereof a positioning block 31 and being slipped thereover by a spring 33 . And the lid 23 with a pair of positioning bars 24 is locked in the housing. The abutting block 27 is exactly abutted on the engaging edge 16 of the cam-styled axle sleeve 15 . And referring to FIG. 2, the pull rod 30 extending out of the lid 23 is engaged with a protruding member 19 provided on a lock core rod of a locking member 18 , a circuit board 90 is added to receive the electronic signals to control rotation of the motor 21 .
[0026] As shown in FIG. 4, the inner lock part 40 has a size in coincidence with that of the housing of the outer lock part 10 , the housing is provided at locations therein with screw studs and protruding blocks for screwing connecting and positioning of the remaining members. The inner lock part 40 is provided on the housing surface thereof with a handle 41 for rotating an inner rotation axle 43 ; when the rotation axle 43 is connected with the handle 41 , a spring 42 is provided between them for restoration of the handle 41 . The front and the rear portions of the rotation axle 43 are in different shapes, the front portion in connecting with the handle 41 is a square stub; while the rear portion is a round member which is provided in the center thereof with a recessed axle hole 44 , the axle hole 44 is inserted therein with a second rotation axle 46 which is provided on one end thereof with a recess 461 (as shown in FIG. 2). The round member on the rear portion of the rotation axle 43 is provided laterally with a protruding post 45 able to move an inner pull rod 47 which is provided on the other end thereof with an elongate slot 48 . The elongate slot 48 is to be slipped over a protruding post 50 provided on an axle seat 49 ; the axle seat 49 is provided thereon with a cross hole 51 which is provided on the inner end thereof with a cross mandrel 52 , and is further provided on the outer end thereof with an indicating disk 53 .
[0027] The dead bolt 60 and the spring-loaded latch bolt 70 is mounted together on the door panel 80 when the present invention is connected with the door panel 80 , as shown in FIG. 5. The inner lock part 40 is mounted inside the door panel 80 , while the outer lock part 10 is mounted outside the door panel 80 opposite to the inner lock part 40 . The recess 461 on the end of the second rotation axle 46 linked up with the handle 41 of the inner lock part 40 is connected with the protruding post 133 on the end face of the rotation axle 13 linked up with the handle 11 of the outer lock part 10 , and the dead bolt 60 and the spring-loaded latch bolt 70 are both linked up with the inner lock part 40 ; the dead bolt 60 is controlled by the cross mandrel 52 , while the spring-loaded latch bolt 70 is controlled by the second rotation axle 46 ; the cross mandrel 52 is linked up with the rotation axle 43 through the inner pull rod 47 and thereby is synchronically controlled by the handle 41 . Referring simultaneously to FIGS. 5 a , 5 b , and 5 c , when the dead bolt 60 and the spring-loaded latch bolt 70 are connected with each other, the abutting block 27 of the control device 20 tightly abuts against the engaging edge 16 of the cam-styled axle sleeve 15 to position the cam-styled axle sleeve 15 against moving. Meanwhile, although the protruding post 133 of the rotation axle 13 is connected with the recess 461 on the end of the second rotation axle 46 , it is unable to move the second rotation axle 46 . Concequently no matter clockwise or counterclockwise the handle 11 only swivel the rotation axle 13 but not move the second rotation axle 46 , and thereby the door panel 80 is unable to open.
[0028] Referring simultaneously to FIGS. 6 6 a , and 6 b , the locking member 18 can be a conventional lock with a lock hole for inserting therein of a key, the lock core rod connected on the rear end of the locking member 18 is provided in the middle thereof with the protruding member 19 ; when the key is rotated in the lock hole, the protruding member 19 of the lock core rod is rotated to move the pull rod 30 and move up the abutting block 27 to move forwards the cam-styled axle sleeve 15 ; the square axle hole 17 of the cam-styled axle sleeve 15 is slipped over the second rotation axle 46 to make the rotation axle 13 of the outer lock part 10 and the rotation axle 43 of the inner lock part 40 as an integral whole. When the handle 11 is pressed down, the rotation axle 13 , the cam-styled axle sleeve 15 , the second rotation axle 46 , and the rotation axle 43 are swiveled synchronically. The spring-loaded latch bolt 70 is moved by the second rotation axle 46 , and the protruding post 45 of the rotation axle 43 is linked up to move the inner pull rod 47 . So that the protruding post 50 restrained by the elongate slot 48 and the axle seat 49 linked up with the protruding post 50 are synchronically rotated therewith. The cross mandrel 52 inserted in the cross hole 51 is linked up with the dead bolt 60 which is contracted together with the spring-loaded latch bolt 70 into the door panel 80 to allow easy opening of the door panel 80 . And the indicating disk 53 provided exteriorly of the inner lock part 40 and slipped over the cross hole 51 is rotated too, thereby, a person can be aware by visual viewing of the state of opening/closing.
[0029] The outer lock part 10 and the inner lock part 40 are provided with spring leaves 101 , 401 , and the rotation axles 13 , 43 linked up with the handles 11 , 41 are provided on the exterior peripheries respectively thereof with positioning notches 132 , 431 . By virtue that the springs 12 , 42 are respectively provided between the rotation axles 13 , 43 and the handles 11 , 41 , the rotation axles 13 , 43 will be rebounded respectively by the springs 12 , 42 and are positioned respectively by the positioning notches 132 , 431 and the spring leaves 101 , 401 to restore the handles 11 , 41 to their original positions.
[0030] Referring to FIG. 7, going outdoors needs only to press down the handle 41 . Because the dead bolt 60 and the spring-loaded latch bolt 70 on the door panel 80 are directly controlled by the second rotation axle 46 and the cross mandrel 52 respectively, and these two are synchronically linked up by the rotation axle 43 , the door panel 80 can be opened by pressing down the handle 41 . In any emergency situation such as conflagration or earthquake the door panel 80 can be opened easily as described above.
[0031] To lock the door panel 80 from the outdoors, the locking member 18 is inserted with a key for turning, and the protruding member 19 of the lock core rod is rotated to move the abutting block 27 , and further move forwards the cam-styled axle sleeve 15 to make integral of the rotation axle 13 with the second rotation axle 46 ; then the handle 11 is pulled to swivel to make reversion of the rotation axle 13 , the cam-styled axle sleeve 15 , the second rotation axle 46 and the rotation axle 43 so that the dead bolt 60 can be extended out of the door panel 80 and lock the latter. To lock the door panel 80 from the indoors, it needs only to pull up the handle 41 , such as is shown in FIG. 8, to make reversion of the rotation axle 43 to move the second rotation axle 46 and the cross mandrel 52 to thereby extend the dead bolt 60 out of the door panel 80 .
[0032] The control device 20 of the present invention not only can render the locking member 18 to control raising and lowering of the abutting block 27 manually, but also can be added with an electric circuit board 90 to automatically control the motor 21 to render the screw rod 22 of the motor 21 to move the gear 25 ; the eccentric protruding block 26 of the gear 25 can thereby move the abutting block 27 , so that the cam-styled axle sleeve 15 can be positioned and moved forwards. There are many ways to control the electric circuit board 90 , for example, it can be automatically controlled by an externally connected card reader, code reader or a remote control etc., so that the door can be opened in a more convenient and safer way.
[0033] The locking member 18 of the present invention is provided on one side of the outer lock part 10 and is quite close to the door frame; the distance between the outer lock part 10 and the door frame is less than 2 cm; the key for the locking member 18 is in the shape of “L” to provide theft-proofing because it is hard to be pried with a tool or a master key.
[0034] The door lock with a clutch having a cam-styled axle sleeve of the present invention has the following advantages:
[0035] 1. The present invention is provided with a device as a clutch which is composed of a control device and a cam-styled axle sleeve to be able to control integration of rotation axles and in turn to control opening/closing of a door lock practically.
[0036] 2. The dead bolt and the spring-loaded latch bolt of the present invention are directly or indirectly linked up with the rotation axle of the inner lock part, so that the handle of the inner lock part can be directly pressed down to open the door in any situation, which help opening the door for fleeing in an emergency.
[0037] 3. The inner lock part is provided with an indicating disk to indicate the state of whether the dead bolt is locked with different colors or signs so it is very convenient in awareness the state.
[0038] In conclusion, the door lock with a clutch having a cam-styled axle sleeve of the present invention has a brand-new component arrangement and evidently improved function in relating to the door lock devices used presently.
[0039] All modifications and variations to the invention that would be obvious to a person of ordinary skill in the art are deemed to be within the scope of the present invention the nature of which is to be determined from the above description and the appended claims. | 4y
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BACKGROUND OF THE INVENTION
This invention relates to conservation of utilities in hydrogen recycle processes used in oil refineries and petrochemical plants. More specifically, the invention relates to a method of reducing hydrogen recycle flow and thus reducing heating load and compression load in hydrogen recycle processes. Hydrogen recycle processes can be classified into two types: those which produce hydrogen and those which consume hydrogen. Examples of hydrogen-producing processes are catalytic reforming and the various dehydrogenation processes. Hydrogen-consuming processes include hydrogenation, hydrodealkylation, hydrodesulfurization, hydrocracking, and isomerization. FIGS. 1 and 2, which are presented herein as examples, show the basic flow arrangement of most hydrogen recycle processes. A circulating gas flow consisting mainly of hydrogen and including hydrocarbon vapors is maintained in the equipment loop by means of a compressor. Several streams are added to and removed from the loop. It is desirable to maintain the concentration of hydrogen in the reactor above a certain minimum value for each particular process in order to protect catalyst activity and stability and/or product yield structure. These minimum values are known to those skilled in the art by means of experimental data which has been collected by them. If the hydrogen concentration falls below the minimum value in a process where the reactor contains catalyst, the result will be excessive deposit of coke on the catalyst, premature deactivation of the catalyst, and reduction of product yield. In those processes which do not utilize a catalyst, the hydrogen concentration must be maintained above the minimum value in order to protect the yield structure, that is, to maximize the amount of desired product produced by the processing unit and minimize the production of undesirable by-products. A standard method for maintaining the required minimum hydrogen concentration is for an operator of the hydrocarbon processing unit to monitor the quantity of circulating gas flowing by means of a flow indicator and manually accomplish compressor capacity adjustment. An alternative method is to use an automatic controller to monitor the quantity of circulating gas flowing and adjust the capacity of the compressor to maintain the quantity flowing at an appropriate value above the minimum. However, total circulating gas flow is not the variable which it is necessary to control, thus the desired flow value must be set higher than necessary to ensure the existence of an adequate safety margin for hydrogen content of the circulating gas flow.
In addition, variations in cooling efficiency lead to an excessive circulating gas flow. The cooling medium used in the cooler, which is part of the equipment loop shown in FIGS. 1 and 2, is water or ambient air. The temperature of the cooling medium varies with weather conditions and time of day and can vary from hour to hour. As the cooling medium temperature falls, a larger quantity of hydrocarbon vapor condenses out of the cooled stream, thus causing the concentration of hydrogen in the circulating stream to increase. The average molecular weight of the circulating gas stream decreases as hydrogen concentration increases. The flow meter used is normally of the orifice type. As can be seen from an inspection of the well-known orifice flow meter equation and the example presented herein, a lower molecular weight of the circulating gas stream results in a lower flow reading, which is false. This lower flow reading causes the operator or automatic controller to increase compressor capacity or output in order to bring the flow reading back up to its proper value. However, the flow reading is not an accurate indication of hydrogen concentration, because of the changed molecular weight, and the effect is an increase in circulating gas flow which is not necessary to protect the catalyst and does not serve any other desired purpose. Even though a decrease in cooling medium temperature causes an increase in hydrogen concentration, in the absence of instrumentation to show this, it is not possible to act on the decrease, and in fact, it is necessary to adjust the compressor to raise the flow rate back to its former value in order to ensure protection of the catalyst and yield structure. Thus a decrease in the temperature of a cooling medium which is capable of varying from hour to hour results in an unnecessarily large circulating gas flow. The excess circulating gas must be heated and compressed. Reducing the circulating gas flow will result in a decrease in utility usage required to accomplish this. It is possible to control circulating gas composition at a constant value by regulating the quantity of cooling medium passed through the cooler. However, this is not usually a desirable option, since a colder cooling medium yields a colder gas-liquid separator, which enhances liquid product recovery and the purity of the circulating gas. Also, a colder gas-liquid separator results in less hydrogen being dissolved in the liquid product stream and therefore lost from the system.
The art which has been discovered which is closest to the instant invention is disclosed by Bajek and McLaughlin in U.S. Pat. Nos. 3,974,064 and 3,972,804. These patents present a comprehensive control scheme for hydrogen recycle processes. The instant invention can be considered an improvement on those inventions. Those effects of changes in cooling medium temperature which are adverse are recognized and control action is taken to mitigate them. The key process parameter of partial pressure is recognized and used to initiate control action. An excessively large safety margin in hydrogen concentration is not necessary.
BRIEF SUMMARY OF THE INVENTION
It is an object of this invention to provide a means of reducing utility usage in hydrogen recycle processes by reducing the amount of gas which must be circulated and thereby reducing energy required to heat and compress the circulating gas. The concentration of hydrogen is obtained and used to adjust the output of the compressor so that the concentration of hydrogen is at the minimum required to protect the catalyst and/or maintain the yield structure. In one of its broad aspects, the present invention embodies a method consisting of (a) monitoring the concentration of hydrogen in a hydrogen recycle process; (b) comparing said concentration of hydrogen to a previously established value; and (c) adjusting the output of a compressor in response to said comparison to provide a concentration of hydrogen which is equal to said previously established value. In a more specific embodiment of the present invention, the concentration of hydrogen in the reactor is expressed in terms of partial pressure and is obtained by means of measuring the total pressure of the feed stream, measuring the mole fraction of hydrogen in the feed stream, then multiplying mole fraction times total pressure, the product being partial pressure. Other objects and embodiments will become apparent upon consideration of this entire specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 depict typical flow schemes for hydrogen recycle processes used in oil refineries and petrochemical plants.
FIG. 1 depicts a mode of practicing the invention in a hydrogen-consuming process wherein a partial pressure detection apparatus is used to measure the concentration of hydrogen.
FIG. 2 depicts a mode of practicing the invention in a hydrogen-producing process wherein the partial pressure of hydrogen is calculated from measurements of total pressure and mole fraction. Note that the dashed lines represent transmission of control signals to and from items of control hardware and that solid lines drawn to the circles representing instruments denote pipelines containing process fluid.
DETAILED DESCRIPTION OF THE INVENTION
The further description of this invention is presented with reference to the schematic drawings, FIGS. 1 and 2. The drawings are not intended as an undue limitation on the generally broad scope of the invention as set out in the claims. Only those compressors, heaters, heat exchangers, and coolers are shown that are useful in the description of the process. The depiction of other miscellaneous hardware such as pumps, instrumentation and controls, and valves has been omitted as not essential to a clear understanding of the process, the use of such hardware being well within the purview of one skilled in the art.
In FIG. 1, a charge stock stream enters the processing unit through pipeline 1 and is mixed with circulating gas flowing in pipeline 2 by means of mixing pipeline section 3 to form a reactor feed stream in pipeline 20. The rate of charge stock addition is controlled at a particular preset value by flow controller 4 and flow control valve 41. The circulating gas stream flowing in pipeline 2 consists mainly of hydrogen but includes hydrocarbon vapors. The reactor feed stream flows through pipeline 20 to regenerative heat exchanger 5, where it is heated, and then through pipeline 6 to heater 7. The feed stream is heated further in heater 7 and then flows through pipeline 9 to reactor 8, where the desired reactions take place. The effluent stream produced in reactor 8 flows through pipeline 10 to regenerative heat exchanger 5 where it is cooled by giving up its heat to the reactor feed stream. From regenerative heat exchanger 5, the product stream flows through pipeline 11 to cooler 12 where it is further cooled by means of a cooling medium which is water or ambient air. As a result of this cooling, liquid hydrocarbons are condensed. The effluent stream flows from cooler 12 through pipeline 13 to gas-liquid separator 14 where it separates into two streams--a liquid product stream which flows out of the hydrocrabon processing unit through pipeline 15 and a hydrogen and hydrocarbon vapor stream, a portion of which flows through pipeline 16 to compressor 19. Pipeline 17 is connected to pipeline 16 and is used to supply hydrogen to the hydrocarbon processing unit from a source outside of the unit. Pressure controller 18 and pressure control valve 42 regulate the addition of hydrogen so that a constant preset pressure will be maintained at the suction of compressor 19. As hydrogen is consumed in the reactor, the pressure decreases, causing the valve to open to allow hydrogen to flow into the hydrocarbon processing unit. Flow indicator 21 provides a measurement of gas flow at the outlet of compressor 19; however, it is accurate only at one particular set of operating conditions, as explained earlier. Hydrogen and hydrocarbon vapor flow out of the hydrocarbon processing unit through pipeline 38. The flow is controlled by flow control valve 37 and flow controller 34 to a value set by the plant operator. The vent flow is made necessary by the presence of light hydrocarbons in the circulating gas stream. Some light hydrocarbons enter the system through pipeline 17 as part of the hydrogen feed stream, which is not pure hydrogen, and some are produced in side reactions taking place in reactor 8. While some of the light hydrocarbons leave the system dissolved in the liquid product stream, there is usually an increase in concentration over time unless a vent stream is employed. Thus the purpose of the vent stream is to remove light hydrocarbons from the process, as they would interfere with the desired reactions. The principle is similar to that of cooling tower blow-down, where a continuous stream of water is withdrawn to keep water hardness at an acceptably low level. The vent stream usually contains 60 mole percent or more of hydrogen.
FIG. 1 shows the instrumentation necessary to practice an embodiment of the invention. Hydrogen concentration can be expressed as partial pressure of hydrogen. The partial pressure of hydrogen in the effluent stream in pipeline 10 is measured by a partial pressure sensor 22 such as that disclosed by H. A. Hulsberg in U.S. Pat. Nos. 2,671,336 and 2,671,337. Pressure transmitter 23, of conventional design, is used in conjunction with the partial pressure sensor 22 and provides a signal to a conventional automatic controller 24 which adjusts compressor capacity to maintain a preset value of hydrogen partial pressure. Compressor capacity is changed by adjusting inlet guide vanes or adjusting the speed of the compressor. Thus only the amount of hydrogen is circulated that is required to meet the minimum necessary to protect the catalyst and/or maintain the yield structure. By means of reducing the hydrogen flow, the power needed by the compressor driving means is reduced and the quantity of fuel burned to provide heat at heater 7 is reduced. Each of the equipment items shown in FIGS. 1 and 2 may consist of several individual pieces of equipment. For example reactor 8 may consist of a single vessel or may consist of several reaction vessels with provisions to reheat the process stream between vessels. Also, equipment may be added to this basic flow scheme. For example, the circulating gas stream may be passed through equipment designed to remove hydrogen sulfide. These variations and additions to the basic simple schematic are well known to those skilled in the art of hydrocarbon processing.
FIG. 2 differs from FIG. 1 in that, since it depicts a hydrogen-producing process, the hydrogen feed stream and vent stream are replaced by a single hydrogen removal stream and a different embodiment of the invention is depicted. Hydrogen produced in the reactor is removed by removing a portion of the hydrogen and hydrocarbon vapor stream flowing from gas-liquid separator 14 by means of pipeline 43. Pressure controller 45 and pressure control valve 44 regulate the removal of gas so that a constant preset pressure will be maintained at the suction of compressor 19. As hydrogen and hydrocarbon vapors are generated, the pressure increases, causing the valve to open to allow gas to flow out of the hydrocarbon processing unit. In the embodiment of the invention depicted in FIG. 2, the pressure in pipeline 9 is sensed by a conventional pressure transmitter 25. The mole fraction of hydrogen in pipeline 9 is sensed by concentration transmitter 26, which may be a conventional thermal conductivity analyzer such as the 7C series sold by Beckman Instruments, Inc. The product of pressure times mole fraction, which is partial pressure, is obtained in multiplying relay 27. Automatic controller 28 adjusts the capacity of compressor 19 to maintain a preset value of partial pressure. As in FIG. 1 the concentration of hydrogen is set at the minimum value, thus accomplishing conservation of utilities.
In FIG. 1, the sensing point for hydrogen concentration is downstream of the reactor 8, at pipeline 10, rather than upstream of the reactor as shown in FIG. 2. Since the reaction of FIG. 1 consumes hydrogen, the hydrogen concentration will decrease from the inlet to the outlet of the reactor means. The point of lowest hydrogen concentration will be at the outlet of the reactor means, i.e., in the reactor effluent stream. In contrast, in a hydrogen-producing process such as that of FIG. 2, the point of lowest hydrogen concentration will be at the entrance to the reactor means. The hydrogen concentration should be measured at the point where it is expected to be lowest in order to achieve the goal of maintaining as low as possible a concentration in order to conserve utilities while still protecting the catalyst and/or yield structure. In some cases, it may be desirable to vary the location of the hydrogen concentration sensor while keeping it downstream of the reactor means. The sensor can be located in pipeline 10 or pipeline 11. The reason for changing sensor location would normally be to expose it to less severe conditions. The considerations involved in choice of sensor location are familiar to those skilled in the art. For example, it must not be placed in pipeline 11 if liquid drops condense out in heat exchanger 5. The method of measuring hydrogen content is totally independent of sensing location. For example, a partial pressure sensor as disclosed in the Hulsberg patents and an associated pressure transmitter can be used in place of pressure transmitter 25 and concentration transmitter 26 in FIG. 2.
The functions performed by the automatic controllers and arithmetic relays shown in FIGS. 1 and 2 can be accomplished by a digital computer which would receive process measurements and provide control signals in place of the automatic controllers and arithmetic relays. The method of practicing the invention is not changed by substitution of a digital computer for the automatic controllers and arithmetic relays and the depiction of controllers and relays in the Figures can be taken as showing computer functions. With use of a digital computer, different control algorithms are possible which might prove more efficient under certain circumstances. Control by a digital computer or microprocessor-based control units are included within the scope of this invention.
It is important to note that partial pressure is the parameter most relevant to protection of catalyst and yield structure. The invention can be practiced using any convenient method of measuring hydrogen concentration. However, for maximum precision, concentration of hydrogen should be expressed in terms of partial pressure. In the context of this invention, partial pressure is considered to be a form of expression of concentration. Often, the concentration of hydrogen can be measured by any convenient means without any loss of precision, since system pressure is relatively constant. But mole fraction, volume percent, and the like, do not completely correlate with improvement of catalyst activity and stability and yield. Pressure must be taken into account. If the amount of hydrogen in the circulating gas stream is held constant and the pressure is increased, the partial pressure of hydrogen increases. Catalyst activity and stability and yield will be improved by the pressure increase, though percent hydrogen has not changed.
The following example will illustrate the utility savings which are available from the practice of the instant invention. The following Table presents certain operating parameters for a hydrogen recycle process, more specifically a catalytic reforming unit processing 10,000 barrels per day of naphtha charge stock.
______________________________________ CASE A CASE B CASE C______________________________________Separator Temperature, °F. 100 80 80Orifice DP, inches water 42 42 36Circulating Gas, lb-mol/hr 5,271 5,623 5,215Circulating Gas, mol. % Hydro- 86.9 87.8 57.8genCirculating Hydrogen, lb-mol/hr 4,579 4,936 4,579Circulating Gas, mol. wt. 6.82 6.18 6.18Circulating Gas lb/hr 35,940 34,750 32,207Heating Load, 10.sup.6 BTU/hr BASE +0.211 -0.349Compression Load, HP BASE +116 -38______________________________________
Case A shows parameters when the unit shown in FIG. 2 is operating with the design maximum cooling medium temperature, at which the gas-liquid separator 14 operating temperature will be 1OO° F. Orifice DP is the measured pressure drop across the orifice plate at flow indicator 21 and is the value which is converted into flow rate by means of the flow indicator scale. The circulating gas and circulating hydrogen parameters are all taken at pipeline 2. The heating load refers to heat which is supplied to heater 7. Compression load refers to the power required to drive compressor 19.
Case B shows the parameters when the cooling medium temperature is such that gas-liquid separator 14 is operating at 80° F. and the invention is not practiced. Orifice pressure drop is maintained at the same value as Case A by an operator or automatic controller. The amount of hydrogen in the circulating gas stream is increased from Case A. The heating load and compression load is increased from Case A.
Case C shows the same parameters when the cooling medium temperature is the same temperature as Case B but where the invention is practiced. The heat decrease over Case B is 560,000 BTU/hr; allowing for firing inefficiencies, this results in fuel savings of approximately 700,000 BTU/hr. The power savings over Case B is 154 horsepower. On a yearly basis, at realistic 1981 rates of $5.00 per million BTU's, and $350.00 per horsepower-year, and assuming 11 months operation at conditions which average out to Case C conditions, practice of this invention results in a cost savings of approximately $77,500.00 in this relatively small reforming unit. Reforming units of six times the capacity of this unit have been built. | 4y
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FIELD OF THE INVENTION
[0001] The present invention relates to a novel and useful solar energy collector system, more particularly a concentrator-driven, photovoltaic power generator for conversion of solar electromagnetic energy to electrical energy.
BACKGROUND OF THE INVENTION
[0002] Solar energy has served as a means for generating electricity and heat at an accelerated pace. Although solar energy comprises a very abundant source, conversion to useable forms of energy is expensive.
[0003] In the past, many systems have been devised to capture solar radiation. For example, solar panels have been employed in fixed arrays to directly convert solar radiation to electricity. In addition, circulation membranes have been employed to heat water for use within buildings and for use in swimming pools and spas. Other systems employ concave reflectors that concentrate solar radiation substantially at a point, where it is then employed to heat materials or is transferred as light to secondary conversion apparatuses.
[0004] For example, U.S. Pat. Nos. 4,841,946 and 5,540,216 show concave solar power collectors which track movement of the sun and convert the solar radiation into heat.
[0005] U.S. Pat. No. 5,877,874 shows a holographic planar concentrator which collects optical radiation from the sun for conversion through photovoltaic cells into electrical energy. Also, fiber optic light guides transfer collected light to an interior of a building for illumination or for the purpose of producing hot water.
[0006] U.S. Pat. No. 5,581,447 shows a solar skylight apparatus in which light is collected from the sun and transmitted to the inside of a building through a fiber optic cable. The light is then dispersed within a room to provide illumination.
[0007] U.S. Pat. Nos. 4,943,125 and 5,575,860 show solar collectors that employ fiber optic fibers for use as energy sources.
[0008] A solar collection device which is efficient, powerful, and simple in construction would be a notable advance in the field of solar energy production.
SUMMARY OF INVENTION
[0009] The present invention is a novel and useful collection device for capturing and transmitting electromagnetic radiation received from the sun. The present invention incorporates a solar collector, lens(es), an infrared (IR) filter, and photovoltaic cell. Incoming solar radiation striking the face of the parabolic solar collector is reflected and concentrated at the focal point. As the radiation begins to diverge from the focal point, it enters a concave plano lens, from which it exits as a concentrated beam. This beam then passes through an infrared filter, which screens out the infrared portion of the solar spectrum, thus preventing heat damage to, and loss of efficiency of, the photovoltaic cell. The concentrated photon rich visible light portion of the spectrum then strikes and activates the photovoltaic cell, thus generating a flow of electrical energy.
[0010] The device of the present invention utilizes a reflector having a concave reflecting surface. The parabolic reflector is in general known to those skilled in the art. In such reflectors, essentially parallel rays of solar radiation are focused and concentrated at the focal point, thus, intensifying the radiation captured. The reflector is mounted on an existing-type tracking system which is also known in the art; or a novel, custom tracking system, to keep the reflecting surface in direct alignment with the sun from dawn to dusk, as the sun moves across the sky, thereby maximizing power output.
[0011] An intermediary concave-plano lens is disposed at approximately the focal point of the parabolic reflector. The curvature of the concave side of the lens is the same as the curvature of the parabolic curved concave reflector. The concave side of the lens faces the reflector and the plano side of the lens faces the IR filter and the photovoltaic cell. The plano-concave lens converts the converging electromagnetic radiation into a concentrated, parallel-beam of visible-wavelength, electromagnetic radiation.
[0012] In order to eliminate heat from infrared radiation, an infrared (IR) filter is placed between the plano-concave lens and the photovoltaic cell.
[0013] It may be apparent that a novel and useful collection device for capturing and converting electromagnetic radiation described avoce.
[0014] It is therefore an object of the present invention to provide a collection device for capturing and converting visible-wavelength, electromagnetic radiation radiating from the sun into electrical energy that is simple to manufacture and to operate.
[0015] Another object of the present invention is to provide a device for capturing and converting electromagnetic radiation from the sun into electrical energy in an efficient manner.
[0016] A further object of the present invention is to provide a collection device for capturing and converting electromagnetic radiation that is suitable for congested or urban areas.
[0017] A further object of the present invention is to avoid overheating or otherwise damaging the photovoltaic cell during transmission of focused electromagnetic radiation into electrical energy by using an infrared (IR) filter.
[0018] The invention possesses other objects and advantages especially as concerns particular characteristics and features thereof which will become apparent as the specification continues.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a representative side view of the concentrator-driven, photovoltaic power generator 100 of the present invention.
[0020] FIG. 2 is a representative sectional view of the concentrator-driven, photovoltaic power generator 100 of the present invention.
[0021] FIG. 3 is a schematic view of the mechanism of energy conversion/storage sub-system 200 of the present invention.
[0022] FIG. 4 is a schematic view representing transduction of solar energy into electricity.
[0023] For a better understanding of the invention reference is made to the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the prior described drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] The description that follows is presented to enable one skilled in the art to make and use the present invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be apparent to those skilled in the art, and the general principals discussed below may be applied to other embodiments and applications without departing from the scope and spirit of the invention. Therefore, the invention is not intended to be limited to the embodiments disclosed, but the invention is to be given the largest possible scope which is consistent with the principals and features described herein.
[0025] Various aspects of the present invention will evolve from the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the hereinabove delineated drawings.
[0026] The present invention as a whole is shown in the drawings by reference character 100 , and any upper case letter to represent various embodiments thereof. With respect to FIG. 1 , concentrator-driven, photovoltaic power generator 100 consists of a parabolic-shaped reflector 12 and a mobile stand 102 . Specifically, reflector 12 takes the form of a parabolic mirror having an inner reflecting surface 14 and an outer surface 16 which is generally non-reflective. In essence, reflecting surface 14 captures or gathers incoming parallel rays 18 from the sun. Reflecting surface 14 then reflects and focuses converging reflected rays 22 to the focal point 20 . Reflected rays 22 indicate such concentration of electromagnetic radiation to focal point 20 . As shown in FIGS. 1 and 2 , a twice-bent hollow support tubing 150 or equivalent extends from the center of reflector 12 and provides anchor points for the electromagnetic radiation collection/storage system 200 .
[0027] As shown in FIG. 1 , reflector 12 is supported and elevated by mobile stand 102 . In one embodiment, mobile stand 102 may be of a conventional configuration to provide a sturdy and stable base for reflector 12 in the outdoor environment. Reflector 12 is anchored, fixed, and pivots mechanically, flexibly and adjustably on mobile stand 102 . Mechanical coupling device 105 such as a hinge, ball-and-socket joint, universal joint, etc., permits reflector 12 to rotate and move about its center point. This allows a controllable range of two-dimensional motion such that it is capable of tracking the sun as it travels across the sky on a daily orbital basis. Mechanical device 105 can be manually operated or controlled with an electrical/electronic motor. Support stand 102 can be mobile with wheels or other means such as wheels-and-track system 130 so the entire power generator 100 can be moved or relocated to locations that are most receptive to strong sun exposure. Since such two-axis tracking system supports are known in the art, mobile stand 102 is only partially shown in the drawings. In one embodiment, physical locations of the present invention 100 in the wheels-and-track system 130 and titling angles of reflector 12 can both be pre-programmed according to locations of the sun during the day/year.
[0028] FIG. 2 is a representative sectional view of the concentrator-driven, photovoltaic power generator 100 of the present invention. FIG. 3 is a schematic view of the mechanism of concentrator-driven, photovoltaic power generator 200 of the present invention. Referring to FIG. 3 , the concentrator-driven, photovoltaic power generator 200 consists one or more intermediary lens assembly 106 , infrared filter device 108 and photovoltaic cell 112 . The three elements of the concentrator-driven, photovoltaic power generator 200 are installed and supported securely by each of its support stands 152 , 154 and 156 on the twice-bent hollow support tubing 150 which extends from the center of reflector 12 . In one embodiment, the three elements are disposed in a straight line sequence of intermediary lens assembly 106 →infrared filter device 108 →photovoltaic cell 112 with the intermediary lens assembly positioned closest to reflector 12 . The intermediary lens assembly is positioned at the focal point 20 where all converging reflected rays 22 from reflector 12 are gathered. In one embodiment, support tubing 150 is a hollow tubing that has a squarish cross-section and is made of steel, plastic, silicon or other sturdy and yet strong materials. It will be understood by those skilled in the art that support tubing can be substituted with equivalent structural components for achieving the same function.
[0029] In one embodiment, intermediary lens assembly 106 which is a type of optical lens fixed at the focal point 20 , where the converging reflected rays or concentration of electromagnetic radiation 22 enter intermediary lens assembly 106 . Intermediary lens assembly 106 can be in the form of a lens or a lens assembly that alters the converging reflected rays or concentration of electromagnetic radiation 22 into a concentrated, uni-directional flow of solar energy 110 . The optical characteristics such as focal length, shape, i.e., concave, convex or combination thereof, etc., of intermediary lens assembly 106 can be adjusted according to the true dimension of the power generator 100 . In one embodiment, parallel rays 18 from the sun are reflected by reflector 12 to become converging rays 22 at focal point 20 . The main purpose of reflector 12 is to concentrate the energy of parallel rays 18 at focal point 20 for effective energy collection. Subsequently, at and around focal point 20 , converging reflected rays 22 pass through intermediary lens assembly 106 and emerge as a concentrated, uni-directional flow of visible-wavelength solar energy 110 . The present invention minimizes energy loss due to internal reflection or other reasons.
[0030] In one embodiment, intermediary lens assembly 106 is movably fixed to support tubing 150 by its support stand 152 such that the position of the intermediary lens assembly 106 can be adjusted in order to be located at or as close to the focal point 20 as possible for maximum efficiency. Since it is possible that a portion of the uni-directional flow of solar energy 110 will contained energy in the infrared wavelength-range, the system could develop overheating problems. Thus, the uni-directional flow of solar energy 110 , i.e., parallel radiation, leaves intermediary lens assembly 106 and enters infrared filter device 108 .
[0031] Infrared filter device 108 is an infrared cut-off filter, sometimes called an IR filter or heat-absorbing filter. In one embodiment, infrared filter device 108 is movably fixed to support tubing 150 by its support stand 154 . The purpose of infrared filter device 108 is to block infrared wavelength-radiation in the uni-directional flow of solar energy 110 while passing uni-directional flow of filtered solar energy 120 to prevent overheating when it enters photovoltaic cell 112 . In alternative embodiments, other types of filters such as UV filter or other wavelength-specific filters can be added or replaced as needed.
[0032] Filtered uni-directional flow of solar energy 120 , i.e., parallel radiation, leaves infrared filter device 108 and enters photovoltaic cell 112 . Photovoltaic cell 112 is a device that converts the photonic energy of incoming filtered visible wavelength, uni-directional flow of solar energy 120 directly into electricity by the photovoltaic effect. In one embodiment, photovoltaic cell 112 has various electrical characteristics e.g. current, voltage, or resistance to suit specific needs of the present invention 100 . Generally, when photovoltaic cell 112 exposed to uni-directional flow of solar energy 120 , it generates and supports an electric current without the need for any external power source.
[0033] In one embodiment, photovoltaic cell 112 is movably fixed to support tubing 150 by its support stand 156 . Photovoltaic cell 112 is also connected to an electric circuit so the electrical energy generated within can be transmitted to remote locations. In one embodiment, the electric circuit can be installed within the hollow support tubing 150 or other configurations. As best shown in FIG. 4 , in one embodiment, photovoltaic cell 112 converts energy from filtered uni-directional flow of solar energy 120 into electrical energy denoted by electrical potential 402 . Electrical potential 402 can be coupled to a capacitor or used to recharge batteries for storage of the electrical energy generated, as desired. Alternatively, the energy potential 402 can be used to power electrical devices directly. Users can also connect energy potential 402 to a more elaborate electrical circuit with other electrical components such as transducers, transformers, etc. for other purposes, or provide electrical power to the grid, i.e., puts power back into a private or general municipal electrical power system.
[0034] While in the foregoing, embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such detail without departing from the spirit and principles of the invention.
[0035] Although the invention herein is to be understood as described, these descriptions are merely illustrative of the principles and applications of the present invention. Therefore, it is understood that numerous modifications may be made to the illustrative embodiments and that other modifications maybe devised without departing from the scope and functions of the inventions as defined by the claims to be followed.
[0036] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs. Although any methods and materials similar or equivalent to those described can be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications and patent documents referenced in the present invention are incorporated herein by reference.
[0037] While the principles of the invention have been made clear in illustrative embodiments, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, materials, and components used in the practice of the invention, and otherwise, which are particularly adapted to specific environments and operative requirements without departing from those principles. The appended claims are intended to cover and embrace any and all such modifications, with the limits only of the true purview, spirit and scope of the invention. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application No. 61/312,873, filed on Mar. 11, 2010, the content of which is hereby incorporated by reference in its entirety.
FIELD
[0002] The disclosure describes a buffer and methods of template nucleic acid preparation for highly efficient real-time PCR analysis. In an embodiment, the buffer is suitable for lysis of cells containing a target nucleic acid.
BACKGROUND
[0003] The implementation of high throughput PCR screening has revolutionized modern biology and medicine. Diagnostics, environmental monitoring, blood testing and genotyping are but a few of the fields of research that are impacted by this remarkable analytical tool. Together with the emergence of bioinformatics, scientists are now able to analyze large amounts of genetic information in record time. Nevertheless, the conversion of traditional PCR analysis to a high throughput format necessarily requires that the PCR process be streamlined for efficiency as much as possible whilst preserving the advantages of traditional analytical PCR. This challenge is particularly evident when attempting to detect target DNA sequences extracted from living organisms, such as prokaryotic pathogens, where the need for increased throughput requires that cell lysis and PCR amplification occur in the same reaction buffer without compromising the sensitivity of PCR detection.
SUMMARY
[0004] The present invention is based on a novel lysis reagent formulation for the efficient preparation of a nucleic acid template from cells for high throughput real-time PCR analysis. The formulation of the reagent permits rapid cell lysis and template preparation without the need for template purification and isolation. The reagent therefore dramatically improves throughput of real-time PCR analysis while at the same time preserving the sensitivity of detection.
[0005] Accordingly, the present invention provides novel methods for the preparation of template nucleic acids using a lysis reagent that permits the rapid and sensitive real-time PCR detection of a single molecule of nucleic acid template in as little as 30 cycles of PCR amplification.
[0006] In one aspect, the invention teaches a method of preparing a nucleic acid template for real-time PCR amplification. Cells are lysed in a lysis reagent comprising a buffer with a pH of about 6 to about 9, a zwitterionic detergent at a concentration of about 0.125% to about 2%, an azide at a concentration of about 0.3 to about 2.5 mg/ml, and a protease. After incubating the resulting cell lysate at about 55° C. for about 15 minutes to produce a substantially protein-free cell lysate, the protease is inactivated at about 95° C. for about 10 minutes. The substantially protein-free cell lysate provides a template for real-time PCR amplification reaction in a mixture comprising a pair of amplification primers that can anneal to a target DNA sequence in the cell lysate, a probe comprising a detectable label, DNA and RNA nucleic acid sequences that are substantially complimentary to a region of the target DNA, an amplifying polymerase activity, an amplification buffer, and an RNase H activity. After amplification of the target DNA between the first and second amplification primers, the RNA sequences within the probe can form a RNA:DNA heteroduplex with the complimentary DNA sequences in the target DNA.
[0007] The RNase H activity can be a hot start (i.e., activates only after exposure to very high temperatures). RNase H activity or the activity of a thermostable RNase H or both.
[0008] In another aspect, the invention relates to a method of preparing a nucleic acid template for real-time PCR amplification. Cells are lysed in a lysis reagent comprising a buffer with a pH of about 6 to about 9, a zwitterionic detergent at a concentration of about 0.125% to about 2%, an azide at a concentration of about 0.3 to about 2.5 mg/ml. After incubating the resulting cell lysate at about 55° C. for about 15 minutes, the cell lysate provides a template for real-time PCR amplification reaction in a mixture comprising a pair of amplification primers that can anneal to a target DNA sequence in the cell lysate, a probe comprising a detectable label and DNA and RNA nucleic acid sequences that are substantially complimentary to a region of the target DNA, an amplifying polymerase activity, an amplification buffer, and an RNase H activity. After amplification of the target DNA between the first and second amplification primers, the RNA sequences within the probe can form a RNA:DNA heteroduplex with the complimentary DNA sequences in the target DNA.
[0009] The addition of the cell lysate permits the real-time PCR detection of a single target DNA molecule in the cell lysate that requires less than 40 PCR amplification cycles, less than 35 PCR amplification cycles or less than 30 PCR amplification cycles.
[0010] In certain embodiments, the amplification reaction mixture can include a reverse transcriptase activity. The probe can be fluorescently labeled. The fluorescent label can be a FRET pair.
[0011] In another embodiment the substantially protein-free cell lysate is diluted 5 to 15 fold by the amplification reaction mixture.
[0012] The cells can be gram positive bacterial cells such as Listeria or gram negative cells such as E. coli or Salmonella.
[0013] The buffer can be an acetate or phosphate based buffer, 3-(N-morpholino)propane sulphonic acid (MOPS), N-(2-hydroxyethyl)piperazine-N′-(2-ethane sulphonic acid) (HEPES) or 2-amino-2-hydroxymethyl-1,3-propanediol buffer (Tris).
[0014] The zwitterionic detergent can be 3-[(3-cholamidopropyl)dimethylammonio]-1-propanesulfonate (CHAPS).
[0015] The protease can be proteinase K.
[0016] In another embodiment, the invention discloses a lysis reagent comprising a buffer with a pH of about 6 to about 8, a zwitterionic detergent at a concentration of about 0.125% to about 2%, and an azide at a concentration of about 0.3 to about 2.5 mg/ml, wherein the presence of about a 5-15 fold dilution of the reagent together with the amplification reaction mixture does not inhibit the amplifying polymerase and RNase H enzymatic activities.
[0017] The lysis reagent can contain a buffer having an acetate or phosphate based buffer, 3-(N-morpholino)propane sulphonic acid (MOPS), N-(2-hydroxyethyl)piperazine-N′-(2-ethane sulphonic acid) (HEPES), or 2-amino-2-hydroxymethyl-1,3-propanediol buffer (Tris).
[0018] The zwitterionic detergent can be 3-[(3-cholamidopropyl)dimethylammonio]-1-propanesulfonate (CHAPS).
[0019] In yet another embodiment, the lysis reagent comprises a buffer with a pH of about 6 to about 8, a zwitterionic detergent at a concentration of about 0.125% to about 2%, and an azide at a concentration of about 0.3 to about 2.5 mg/ml, and a protease, wherein, after inactivation of the protease, the presence of about a 5-15 fold dilution of the reagent together with the amplification reaction mixture does not inhibit the amplifying polymerase and RNase H enzymatic activities.
[0020] The buffer can include an acetate based buffer, 3-(N-morpholino)propane sulphonic acid (MOPS), N-(2-hydroxyethyl)piperazine-N′-(2-ethane sulphonic acid) (HEPES), or 2-amino-2-hydroxymethyl-1,3-propanediol buffer.
[0021] The zwitterionic detergent can be 3-[(3-cholamidopropyl)dimethylammonio]-1-propanesulfonate.
[0022] The previously described embodiments have many advantages, including the ability to perform cell lysis and real-time PCR without the need for template purification and dilution. The detection method is fast, accurate, sensitive and suitable for high throughput applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a schematic representation of CataCleave probe technology.
[0024] FIG. 2 is a schematic representation of real-time CataCleave probe detection of PCR amplification products.
[0025] FIG. 3A is the output of a real-time PCR reaction using CataCleave probe to detect Salmonella DNA in the presence of different lysis reagents (CZ1-7 & 0.125X TZ).
[0026] FIG. 3B is the output of a real-time PCR reaction using CataCleave probe to detect Listeria DNA in the presence of different concentrations of lysis reagent.
[0027] FIG. 4 is the output of a real-time PCR reaction using CataCleave probe to detect target DNA sequences in a Listeria cell lysate obtained using different concentrations of lysis reagent.
[0028] FIG. 5 is the output of a real-time PCR reaction using CataCleave probe to detect low concentrations of Listeria cells using a preferred lysis solution.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The practice of the embodiments described herein employs, unless otherwise indicated, conventional molecular biological techniques within the skill of the art. Such techniques are well known to the skilled worker, and are explained fully in the literature. See, e.g., Ausubel, et al., ed., Current Protocols in Molecular Biology, John Wiley & Sons, Inc., NY, N.Y. (1987-2008), including all supplements; Sambrook, et al., Molecular Cloning: A Laboratory Manual, 2nd Edition, Cold Spring Harbor, N.Y. (1989).
[0030] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art. The specification also provides definitions of terms to help interpret the disclosure and claims of this application. In the event a definition is not consistent with definitions elsewhere, the definition set forth in this application will control.
[0031] As used herein, the term “cells” can refer to prokaryotic or eukaryotic cells.
[0032] In one embodiment, the term “cells” can refer to microorganisms such as bacteria including, but not limited to gram positive bacteria, gram negative bacteria, acid-fast bacteria and the like. In certain embodiments, the “cells” to be tested may be collected using swab sampling of surfaces. In other embodiments, the “cells” can refer to pathogenic organisms.
[0033] As used herein, gram positive bacteria include, but are not limited to, Actinomedurae, Actinomyces israelii, Bacillus anthracis, Bacillus cereus, Clostridium botulinum, Clostridium difficile, Clostridium perfringens, Clostridium tetani, Corynebacterium, Enterococcus faecalis, Listeria monocytogenes, Nocardia, Propionibacterium acnes, Staphylococcus aureus, Staphylococcus epiderm, Streptococcus mutans, Streptococcus pneumoniae and the like.
[0034] As used herein, gram negative bacteria including, but are not limited to, Afipia fielis, Bacteriodes, Bartonella bacilliformis, Bortadella pertussis, Borrelia burgdorferi, Borrelia recurrentis, Brucella, Calymmatobacterium granulomatis, Campylobacter, Escherichia coli, Francisella tularensis, Gardnerella vaginalis, Haemophilius aegyptius, Haemophilius ducreyi, Haemophilius influenziae, Heliobacter pylori, Legionella pneumophila, Leptospira interrogans, Neisseria meningitidia, Porphyromonas gingivalis, Providencia sturti, Pseudomonas aeruginosa, Salmonella enteridis, Salmonella typhi, Serratia marcescens, Shigella boydii, Streptobacillus moniliformis, Streptococcus pyogenes, Treponema pallidum, Vibrio cholerae, Yersinia enterocolitica, Yersinia pestis and the like.
[0035] As used herein, acid-fast bacteria include, but are not limited to, Myobacterium avium, Myobacterium leprae, Myobacterium tuberculosis and the like.
[0036] In other embodiments, the “cells” can refer to other bacteria not falling into the other three categories including, but are not limited to, Bartonella henselae, Chlamydia psittaci, Chlamydia trachomatis, Coxiella burnetii, Mycoplasma pneumoniae, Rickettsia akari, Rickettsia prowazekii, Rickettsia rickettsii, Rickettsia tsutsugamushi, Rickettsia typhi, Ureaplasma urealyticum, Diplococcus pneumoniae, Ehrlichia chafensis, Enterococcus faecium, Meningococci and the like.
[0037] In yet other embodiment, the term “cells” can refer to fungi including, but are not limited to, Aspergilli, Candidae, Candida albicans, Coccidioides immitis, Cryptococci, and combinations thereof.
[0038] In another embodiment, the term “cells” can refer to parasitic microbes including, but are not limited to, Balantidium coli, Cryptosporidium parvum, Cyclospora cayatanensis, Encephalitozoa, Entamoeba histolytica, Enterocytozoon bieneusi, Giardia lamblia, Leishmaniae, Plasmodii, Toxoplasma gondii, Trypanosomae, trapezoidal amoeba and the like.
[0039] In another embodiment, the term “cells” can refer to parasites including worms (e.g., helminthes), particularly parasitic worms including, but not limited to, Nematoda (roundworms, e.g., whipworms, hookworms, pinworms, ascarids, filarids and the like), Cestoda (e.g., tapeworms) and the like.
[0040] As used herein, “zwitterionic detergent” refers to detergents exhibiting zwitterionic character (e.g., does not possess a net charge, lacks conductivity and electrophoretic mobility, does not bind ion-exchange resins, breaks protein-protein interactions), including, but not limited to, CHAPS, CHAPSO and betaine derivatives, e.g. preferably sulfobetaines sold under the brand names Zwittergent® (Calbiochem, San Diego, Calif.) and Anzergent® Anatrace, Inc.; Maumee, Ohio).
[0041] Examplary zwitterionic detergents for use in practicing the invention include those sold under the brand names Zwittergent® and Anzergent® having the chemical names of: n-Tetradecyl-N, N-dimethyl-3-ammonio-1-propanesulfonate, n-octyl-N,N-dimethyl-3-amraonio-1-propanesulfonate, n-decyl-N,N-dimethyl-3-ammonio-1-propanesulfonate, and n-dodecyl-N,N-dimethyl-3-ammonio-1-propanesulfonate.
[0042] Exemplary detergents of the present invention can be purchased under the brand names, for example, of: Anzergent 3-14, Analytical Grade; Anzergent 3-8, Analytical Grade; Anzergent 3-10, Analytical Grade; Anzergent 3-12, Analytical Grade, respectively or zwittergent 3-8, zwittergent 3-10, zwittergent 3-12 and zwittergent 3-14, CHAPS, CHAPSO, ApolO and Apol2.
[0043] In one embodiment, the zwitterionic detergent is CHAPS (CAS Number: 75621-03-3; available from SIGMA-ALDRICH product no. C3023-1G), an abbreviation for 3-[(3-cholamidopropyl)dimethylammonio]-1-propanesulfonate (described in further detail in U.S. Pat. No. 4,372,888) having the structure:
[0000]
[0044] In a further embodiment, CHAPS is present at a concentration of about 0.125% to about 2% weight/volume (w/v) of the total composition. In a further embodiment, CHAPS is present at a concentration of about 0.25% to about 1% w/v of the total composition. In yet another embodiment, CHAPS is present at a concentration of about 0.4% to about 0.7% w/v of the total composition.
[0045] In another embodiment, the zwitterionic detergent is CHAPSO (CAS Number: 82473-24-3; available from FLUKA, Product number 26675), an abbreviation for 3-[(3-cholamidopropyl)dimethylammonio]-2-hydroxy-1-propanesulfonate and having the structure:
[0000]
[0046] In a further embodiment, CHAPSO is present at a concentration of about 0.125% to about 2% w/v of the total composition. In a further embodiment, CHAPSO is present at a concentration of about 0.25% to about 1% w/v of the total composition. In yet another embodiment, CHAPSO is present at a concentration of about 0.4% to about 0.7% w/v of the total composition.
[0047] As used herein, the term “buffer” refers to a composition that can effectively maintain the pH value between 6 and 9, with a pK a at 25° C. of about 6 to about 9. The buffer described herein is generally a physiologically compatible buffer that is compatible with the function of enzyme activities and enables biological macromolecules to retain their normal physiological and biochemical functions.
[0048] Examples of buffers include, but are not limited to, HEPES ((4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid), MOPS (3-(N-morpholino)-propanesulfonic acid), N-tris(hydroxymethyl)methylglycine acid (Tricine), tris(hydroxymethyl)methylamine acid (Tris), piperazine-N,N′-bis(2-ethanesulfonic acid) (PIPES) and acetate or phosphate containing buffers (K 2 HPO 4 , KH 2 PO 4 , Na 2 HPO 4 , NaH 2 PO 4 ) and the like.
[0049] The term “azide” as used herein is represented by the formula —N 3 . In one embodiment, the azide is sodium azide NaN 3 (CAS number 26628-22-8; available from SIGMA-ALDRICH Product number: S2002-25G) that acts as a general bacterioside.
[0050] The term “protease,” as used herein, is an enzyme that hydrolyses peptide bonds (has protease activity). Proteases are also called, e.g., peptidases, proteinases, peptide hydrolases, or proteolytic enzymes. The proteases for use according to the invention can be of the endo-type that act internally in polypeptide chains (endopeptidases). In one embodiment, the protease can be the serine protease, proteinase K (EC 3.4.21.64; available from Roche Applied Sciences, recombinant proteinase K 50 U/ml (from Pichia pastoris ) Cat. No. 03 115 887 001).
[0051] Proteinase K is used to digest protein and remove contamination from preparations of nucleic acid. Addition of proteinase K to nucleic acid preparations rapidly inactivates nucleases that might otherwise degrade the DNA or RNA during purification. It is highly-suited to this application since the enzyme is active in the presence of chemicals that denature proteins and it can be inactivated at temperatures of about 95° C. for about 10 minutes.
[0052] In one embodiment, lysis of gram positive and gram negative bacteria, such as Listeria, Salmonella, and E. Coli requires the lysis reagent include proteinase K (1 mg/ml). Protein in the cell lysate is digested by proteinase K for 15 minutes at 55° C. followed by inactivation of the proteinase K at 95° C. for 10 minutes. After cooling, the substantially protein free lysate is compatible with high efficiency PCR amplification.
[0053] In addition to or in lieu of proteinase K, the lysis reagent can comprise a serine protease such as trypsin, chymotrypsin, elastase, subtilisin, streptogrisin, thermitase, aqualysin, plasmin, cucumisin, or carboxypeptidase A, D, C, or Y. In addition to a serine protease, the lysis solution can comprise a cysteine protease such as papain, calpain, or clostripain; an acid protease such as pepsin, chymosin, or cathepsin; or a metalloprotease such as pronase, thermolysin, collagenase, dispase, an aminopeptidase or carboxypeptidase A, B, E/H, M, T, or U. Proteinase K is stable over a wide pH range (pH 4.0-10.0) and is stable in buffers with zwitterionic detergents.
[0054] The term “lysate” as used herein, refers to a liquid phase with lysed cell debris and nucleic acids.
[0055] As used herein, the term “substantially protein free” refers to a lysate where most proteins are inactivated by proteolytic cleavage by a protease. Protease may include proteinase K. Addition of proteinase K during cell lysis rapidly inactivates nucleases that might otherwise degrade the target nucelic acids. The “substantially protein free” lysate may be or may not be subjected to a treatment to remove inactivated proteins.
[0056] As used herein, the phrase “does not inhibit said amplifying polymerase and RNase H enzymatic activities” means the presence of the lysis reagent decreases the amplifying polymerase and RNase H enzymatic activities by 0% or by less than about 1% or by less than about 2% or by less than about 5% or by less than about 10% or by less than about 25% as compared to the amplifying polymerase and RNase H enzymatic activities in the absence of the lysis reagent.
[0057] As used herein, the term “nucleic acid” refers to an oligonucleotide or polynucleotide, wherein said oligonucleotide or polynucleotide may be modified or may comprise modified bases. Oligonucleotides are single-stranded polymers of nucleotides comprising from 2 to 60 nucleotides. Polynucleotides are polymers of nucleotides comprising two or more nucleotides. Polynucleotides may be either double-stranded DNAs, including annealed oligonucleotides wherein the second strand is an oligonucleotide with the reverse complement sequence of the first oligonucleotide, single-stranded nucleic acid polymers comprising deoxythymidine, single-stranded RNAs, double stranded RNAs or RNA/DNA heteroduplexes. Nucleic acids include, but are not limited to, genomic DNA, cDNA, hnRNA, snRNA, mRNA, rRNA, tRNA, fragmented nucleic acid, nucleic acid obtained from subcellular organelles such as mitochondria or chloroplasts, and nucleic acid obtained from microorganisms or DNA or RNA viruses that may be present on or in a biological sample. Nucleic acids may be composed of a single type of sugar moiety, e.g., as in the case of RNA and DNA, or mixtures of different sugar moieties, e.g., as in the case of RNA/DNA chimeras.
[0058] As used herein, the term “label” or “detectable label” can refer to any chemical moiety attached to a nucleotide, nucleotide polymer, or nucleic acid binding factor, wherein the attachment may be covalent or non-covalent. Preferably, the label is detectable and renders said nucleotide or nucleotide polymer detectable to the practitioner of the invention. Detectable labels include luminescent molecules, chemiluminescent molecules, fluorochromes, fluorescent quenching agents, colored molecules, radioisotopes or scintillants. Detectable labels also include any useful linker molecule (such as biotin, avidin, streptavidin, HRP (horseradish peroxidase), protein A, protein G, antibodies or fragments thereof, Grb2, polyhistidine, Ni 2+ , FLAG tags, myc tags), heavy metals, enzymes (examples include alkaline phosphatase, peroxidase and luciferase), electron donors/acceptors, acridinium esters, dyes and calorimetric substrates. It is also envisioned that a change in mass may be considered a detectable label, as is the case of surface plasmon resonance detection. The skilled artisan would readily recognize useful detectable labels that are not mentioned above, which may be employed in the operation of the present invention.
[0059] Solely, for illustrative purposes, the method of using the lysis reagent for nucleic acid template preparation is disclosed below in the context of CataCleave PCR or RT-PCR detection of the bacterial pathogen, Salmonella. CataCleave PCR will be explained hereinafter.
Selection of Salmonella Target Sequence
[0060] As used herein, the term “target” nucleic acid sequence refers to a nucleic acid sequence or structure to be detected or characterized. Exemplary target nucleic acid sequences include, but are not limited to, genomic DNA or genomic RNA. In one embodiment, a “target” nucleic acid sequence can serve as a template for amplification in a PCR reaction or reverse transcription PCR reaction. In one embodiment, the “target” nucleic acid sequence can refer to a nucleic acid sequence present in the nucleic acid of an organism or a sequence complementary thereto, which is not present in the nucleic acids of other species.
[0061] In one embodiment, a Salmonella nucleic acid sequence targeted for DNA amplification is first selected from Salmonella nucleic sequences known in the art. As used herein, the term “ Salmonella target sequence” refers to a DNA or RNA sequence comprising the nucleic acid sequence of a bacterium of the genus Salmonella. It includes but is not limited to, species S. enterica and S. bongori that include, but are not limited to, the subspecies: enterica (I), salamae (II), arizonae (IIIa), diarizonae (IIIb), houtenae (IV), and indica (VI). Exemplary serogroups and serovars of the subspecies Salmonella enterica can be found in the U.S. Pat. No. 7,659,381, which is incorporated herein by reference in its entirety.
[0062] Exemplary Salmonella nucleic acid sequences that may be targeted for amplification according to the present invention are taught by the following publications: Liu W Q et al., “ Salmonella paratyphi C: genetic divergence from Salmonella choleraesuis and pathogenic convergence with Salmonella typhi ”, PLoS One, 2009; 4(2):e4510; Thomson N R et al., “Comparative genome analysis of Salmonella enteritidis PT4 and Salmonella gallinarum 287/91 provides insights into evolutionary and host adaptation pathways,” Genome Res, October 2008; 18(10):1624-37; Encheva V et al., “Proteome analysis of serovars typhimurium and Pullorum of Salmonella enterica subspecies I.”, BMC Microbiol, Jul. 18, 2005; 5:42; McClelland M et al., “Comparison of genome degradation in Paratyphi A and Typhi, human-restricted serovars of Salmonella enterica that cause typhoid”, Nat Genet, December 2004; 36(12):1268-74; Chiu C H et al., “ Salmonella enterica serotype Choleraesuis: epidemiology, pathogenesis, clinical disease, and treatment,” Clin Microbiol Rev, April 2004; 17(2):311-22; Deng W et al., “Comparative genomics of Salmonella enterica serovar Typhi strains Ty2 and CT18,” J Bacteriol, April 2003; 185(7):2330-7; Parkhill J et al., “Complete genome sequence of a multiple drug resistant Salmonella enterica serovar Typhi CT18.”, Nature, Oct. 25, 2001; 413(6858):848-52; McClelland M et al., “Complete genome sequence of Salmonella enterica serovar typhimurium LT2,” Nature, Oct. 25, 2001; 413(6858):852-6, of which contents are incorporated herein by reference. An exemplary nucleotide sequence of the complete 4857432 by genome of Salmonella enterica subsp. enterica serovar typhimurium str. LT2 is available under Genbank Accession No. NC — 003197.
[0063] In one embodiment, the amplification probe, having the sequence of SEQ ID NO: 3, anneals to the target Salmonella invA nucleic acid sequence.
[0064] In another embodiment, the target nucleic acid sequence is a region found within the Salmonella -specific invA gene nucleic acid sequence having the following DNA sequence:
[0000]
SEQ ID NO: 4, Salmonella enterica InvA gene (GenBank
Accession No.: U43272.1):
AACAGTGCTCGTTTACGACCTGAATTACTGATTCTGGTACTAATGGTGATGATCATTTCT
ATGTTCGTCATTCCATTACCTACCTATCTGGTTGATTTCCTGATCGCACTGAATATCGTA
CTGGCGATATTGGTGTTTATGGGGTCGTTCTACATTGACAGAATCCTCAGTTTTTCAACG
TTTCCTGCGGTACTGTTAATTACCACGCTCTTTCGTCTGGCATTATCGATCAGTACCAGC
CGTCTTATCTTGATTGAAGCCGATGCCGGTGAAATTATCGCCACGTTCGGGCAATTCGTT
ATTGGCGATAGCCTGGCGGTGGGTTTTGTTGTCTTCTCTATTGTCACCGTGGTCCAGTTT
ATCGTTATTACCAAAGGTTCAGAACGCGTCGCGGAAGTCGCGGCCCGATTTTCTCTGGAT
GGTATGCCCGGTAAACAGATGAGTATTGATGCCGATTTGAAGGCCGGTATTATTGATGCG
GATGCTGCGCGCGAACGGCGAAGCGTACTGGAAAGGGAAAGCCAGCTTTACGGTTCCTTT
GACGGTGCGATGAAGTTTATCAAAGGTGACGCTATTGCCGGCATCATTATTATCTTTGTG
AACTTTATTGGCGGTATTTCGGTGGGGATGACCCGCCATGGTATGGATTTGTCCTCCGCT
CTGTCTACTTATACCATGCTGACCATTGGTGATGGTCTTGTCGCCCAGATCCCCGCATTG
TTGATTGCGATTAGTGCCGGTTTTATCGTGACTCGCGTAAATGGCGATAGCGATAATATG
GGGCGGAATATCATGACGCAGCTGTTGAACAACCCATTTGTATTGGTTGTTACGGCTATT
TTGACCATTTCAATGGGAACTCTGCCGGGATTCCCGCTGCCGGTATTTGTTATTTTATCG
GTGGTTTTAAGCGTACTCTTCTATTTTAAATTCCGTGAAGCAAAACGTAGCGCCGCCAAA
CCTAAAACCAGCAAAGGCGAGCAGCCGCTTAGTATTGAGGAAAAAGAAGGGTCGTCGTTG
GGACTGATTGGCGATCTCGATAAAGTCTCTACAGAGACCGTACCGTTGATATTACTTGTG
CCGAAGAGCCGGCGTGAAGATCTGGAAAAAGCTCAACTTGCGGAGCGTCTACGTAGTCAG
TTCTTTATTGATTATGGCGTGCGCCTGCCGGAAGTATTGTTACGCGATGGCGAGGGCCTG
GACGATAACAGCATCGTATTGTTGATTAATGAGATCCGTGTTGAACAATTTACGGTCTAT
TTTGATTTGATGCGAGTGGTAAATTATTCCGATGAAGTCGTGTCCTTTGGTATTAATCCA
ACAATCCATCAGCAAGGTAGCAGTCAGTATTTCTGGGTAACGCATGAAGAGGGGGAGAAA
CTCCGGGAGCTTGGCTATGTGTTGCGGAACGCGCTTGATGAGCTTTACCACTGTCTGGCG
GTGACCGTGGCGCGCAACGTCAATGAATATTTCGGTATTCAGGAAACAAAACATATGCTG
GACCAACTGGAAGCGAAATTTCCTGATTTACTTAAAGAAGTGCTCAGACATGCCACGGTA
CAACGTATATCTGAAGTTTTGCAGCGTTTATTAAGCGAACGTGTTTCCGTGCGTAATATG
AAATTAATTATGGAAGCGCTCGCATTGTGGGCGCCAAGAGAAAAAGATGTCATTAACCTT
GTAGAGCATATTCGTGGAGCAATGGCGCGTTATATTTGTCATAAATTCGCCAATGGCGGC
GAATTACGAGCAGTAATGGTATCTGCTGAAGTTGAGGATGTTATTCGCAAAGGGATCCGT
CAGACCTCTGGCAGTACCTTCCTCAGCCTTGACCCGGAAGCCTCCGCTAATTTGATGGAT
CTCATTACACTTAAGTTGGATGATTTATTGATTGCACATAAAGATCTTGTCCTCCTTACG
TCTGTCGATGTCCGTCGATTTATTAAGAAA
[0065] As used herein, the term “primer” or “amplification primer” refers to an oligonucleotide that acts as a point of initiation of DNA synthesis in a PCR reaction. A primer is usually about 15 to about 35 nucleotides in length and hybridizes to a region complementary to the target sequence. Oligonucleotides may be synthesized and prepared by any suitable methods (such as chemical synthesis), which are known in the art. Oligonucleotides may also be conveniently obtained through commercial sources.
[0066] A person of ordinary skill in the art would easily optimize and identify primers. A number of computer programs (e.g., Primer-Express) are readily available to design optimal primer/probe sets. It will be apparent to one of ordinary skill in the art that the primers and probes based on the nucleic acid information provided (or publicly available with accession numbers) can be prepared accordingly.
[0067] In one embodiment, the pair of amplification primers (i.e., forward primer and reverse primer) can be the pair of primers of SEQ ID NOs: 1 and 2.
[0000]
5′-TCG TCA TTC CAT TAC CTA CC
(SEQ ID NO: 1)
5′ TAC TGA TCG ATA ATG CCA GAC GAA
(SEQ ID NO: 2)
[0068] A “primer dimer” is a potential by-product in PCR that consists of primer molecules that have partially hybridized to each other because of strings of complementary bases in the primers. As a result, the DNA polymerase amplifies the primer dimer, leading to competition for PCR reagents, thus potentially inhibiting amplification of the DNA sequence targeted for PCR amplification. In real-time PCR, primer dimers may interfere with accurate quantification by reducing sensitivity.
[0069] Primer sequences for the detection of Salmonella are screened for the formation of primer-dimer. PCR reactions are performed using pairs of forward and reverse primers in the presence of SYBR Green I. The fluorescence emission intensity of this dye increases when it becomes intercalated into duplex DNA and therefore can serve as a non-specific probe in nucleic acid amplification reactions. The reactions are performed in a suitable reaction buffer described containing 800 nM of forward and reverse primer, thermostable DNA polymerase, and SYBR Green I. The resulting increase in SYBR Green I fluorescence emission can be detected in real-time using a suitable instrument, such as the Applied Biosystems 7500 Fast Real-Time PCR System or the Biorad CFX96 real-time PCR thermocycler. Primer-dimer formation leads to a characteristic sigmoidal shaped emission profile similar to that seen in the presence of primer-specific template DNA. The terms “annealing” and “hybridization” are used interchangeably and mean the base-pairing interaction of one nucleic acid with another nucleic acid that results in formation of a duplex, triplex, or other higher-ordered structure. In certain embodiments, the primary interaction is base specific, e.g., A/T and G/C, by Watson/Crick and Hoogsteen-type hydrogen bonding. In certain embodiments, base-stacking and hydrophobic interactions may also contribute to duplex stability.
[0070] As used herein, the term “substantially complementary” refers to two nucleic acid strands that are sufficiently complimentary in sequence to anneal and form a stable duplex. The complementarity does not need to be perfect; there may be any number of base pair mismatches, for example, between the two nucleic acids. However, if the number of mismatches is so great that no hybridization can occur under even the least stringent hybridization conditions, the sequence is not a substantially complementary sequence. When two sequences are referred to as “substantially complementary” herein, it means that the sequences are sufficiently complementary to each other to hybridize under the selected reaction conditions such as stringent hybridization condition. The relationship of nucleic acid complementarity and stringency of hybridization sufficient to achieve specificity is well known in the art. Two substantially complementary strands can be, for example, perfectly complementary or can contain from 1 to many mismatches so long as the hybridization conditions are sufficient to allow, for example discrimination between a pairing sequence and a non-pairing sequence. Accordingly, “substantially complementary” sequences can refer to sequences with base-pair complementarity of 100, 95, 90, 80, 75, 70, 60, 50 percent or less, or any number in between, in a double-stranded region.
[0071] A person of skill in the art will know how to design PCR primers flanking a Salmonella genomic sequence of interest. Synthesized oligos are typically between 20 and 26 base pairs in length with a melting temperature, T M of around 55 degrees.
Enrichment for Bacterial Nucleic Acid Sequences in a Test Sample
[0072] An exemplary protocol for detecting a target Salmonella sequence may include the steps of providing a food sample or surface wipe, mixing the sample or wipe with a growth medium and incubating to increase the number or population of Salmonella (“enrichment”), disintegrating Salmonella cells (“lysis”), and subjecting the obtained lysate to amplification and detection of target Salmonella sequence. Food samples may include, but are not limited to, fish such as salmon, dairy products such as milk, and eggs, poultry, fruit juices, meats such as ground pork, pork, ground beef, or beef, vegetables such as spinach or alfalfa sprouts, or processed nuts such as peanut butter.
[0073] The limit of detection (LOD) for food contaminants is described in terms of the number of colony forming units (CFU) that can be detected in either 25 grams of solid or 25 mL of liquid food or on a surface of defined area. By definition, a colony-forming unit is a measure of viable bacterial numbers. Unlike indirect microscopic counts where all cells, dead and living, are counted, CFU measures viable cells. One CFU (usually one bacterial cell) will grow to form a single colony on an agar plate under permissive conditions. The United States Food Testing Inspection Service defines the minimum LOD as 1 CFU/25 grams of solid food or 25 mL of liquid food or 1 CFU/surface area.
[0074] In practice, it is impossible to reproducibly inoculate a food sample or surface with a single CFU and insure that the bacterium survives the enrichment process. This problem is overcome by inoculating the sample at either one or several target levels and analyzing the results using a statistical estimate of the contamination called the Most Probable Number (MPN). As an example, a Salmonella culture can be grown to a specific cell density by measuring the absorbance in a spectrophotometer. Ten-fold serial dilutions of the target are plated on agar media and the numbers of viable bacteria are counted. This data is used to construct a standard curve that relates CFU/volume plated to cell density. For the MPN to be meaningful, test samples at several inoculum levels are analyzed. After enrichment and extraction a small volume of sample is removed for real-time analysis. The ultimate goal is to achieve a fractional recovery of between 25% and 75% (i.e. between 25% and 75% of the samples test positive in the assay using reverse transcriptase-PCR employing a CataCleave probe, which will be explained below). The reason for choosing these fractional recovery percentages is that they convert to MPN values of between 0.3 CFU and 1.375 CFU for 25 gram samples of solid food, 25 mL samples of liquid food, or a defined area for surfaces. These MPN values are chosen because they bracket the required LOD of 1 CFU/sample. With practice, it is possible to estimate the volume of diluted inoculum (based on the standard curve) to achieve these fractional recoveries.
Nucleic Acid Template Preparation
[0075] The reagent for lysing cells can comprise a buffer with a pH of about 6 to about 9, a zwitterionic detergent at a concentration of about 0.125% to about 2%, and an azide at a concentration of about 0.3 to about 2.5 mg/ml. For the lysis of gram negative bacteria, such as Salmonella or E.coli, the lysis reagent may optionally include a protease such as proteinase K. Proteases such as proteinase K are however required for the preparation of PCR template nucleic acid from gram positive bacteria.
[0076] In one embodiment, the 1× lysis reagent is prepared that contains 12.5 mM Tris acetate or Tris-HCl or HEPES (4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid) (pH=7-8), 0.25% (w/v) CHAPS, 0.3125 mg/ml sodium azide. 45 μl 1× lysis agent is then added to 5 μl enrichment sample and incubated at 55° C. for 15 minutes.
[0077] For the lysis of gram negative bacteria, proteinase K to 1 mg/ml may be added to the lysis reagent. After incubation at 55° C. for 15 minutes, the proteinase K is inactivated at 95° C. for 10 minutes to produce a substantially protein free lysate that is compatible with high efficiency PCR or reverse transcription PCR analysis.
PCR Amplification of Salmonella Target Nucleic Acid Sequences
[0078] Once the primers are selected and the cell free lysate containing the target nucleic acid is prepared (see Examples), nucleic acid amplification can be accomplished by a variety of methods, including the polymerase chain reaction (PCR), nucleic acid sequence based amplification (NASBA), ligase chain reaction (LCR), and rolling circle amplification (RCA). The polymerase chain reaction (PCR) is the method most commonly used to amplify specific target DNA sequences.
[0079] “Polymerase chain reaction,” or “PCR,” generally refers to a method for amplification of a desired nucleotide sequence in vitro. The procedure is described in detail in U.S. Pat. Nos. 4,683,202, 4,683,195, 4,800,159, and 4,965,188, the contents of which are hereby incorporated herein in their entirety. Generally, the PCR process consists of introducing a molar excess of two or more extendable oligonucleotide primers to a reaction mixture comprising the desired target sequence(s), where the primers are complementary to opposite strands of the double stranded target sequence. The reaction mixture is subjected to a program of thermal cycling in the presence of a DNA polymerase, resulting in the amplification of the desired target sequence flanked by the DNA primers.
[0080] In one aspect, Salmonella -specific primers which can be used in the embodiments may have a DNA sequence of SEQ ID NOs.: 1-2.
[0081] A probe which can be used in the embodiments of the instant application (sometimes referred to as a “CataCleave probe”) may have the following sequences:
[0082] 5′-/FAM/CGATCAGrGrArArATCAACCAG/IABFQ) (SEQ ID NO: 3) to be used with the primer pair of SEQ ID NOs: 1 and 2 (wherein, lowercase “r” denotes RNA bases (i.e. rG is riboguanosine).
[0083] As used herein, the term “PCR fragment” or “amplicon” refers to a polynucleotide molecule (or collectively the plurality of molecules) produced following the amplification of a particular target nucleic acid. An PCR fragment is typically, but not exclusively, a DNA PCR fragment. An PCR fragment can be single-stranded or double-stranded, or in a mixture thereof in any concentration ratio. A PCR fragment can be about 100 to about 500 nucleotides or more in length.
[0084] An amplification “buffer” is a compound added to an amplification reaction which modifies the stability, activity, and/or longevity of one or more components of the amplification reaction by regulating the amplification reaction. The buffering agents of the invention are compatible with PCR amplification and RNase H cleavage activity. Examples of buffers include, but are not limited to, HEPES (4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid), MOPS (3-(N-morpholino)-propanesulfonic acid), and acetate or phosphate containing buffers and the like. In addition, PCR buffers may generally contain up to about 70 mM KCl and about 1.5 mM or higher MgCl 2 , to about 50-200 μM each of dATP, dCTP, dGTP and dTTP. The buffers of the invention may contain additives to optimize efficient reverse transcriptase-PCR or PCR reactions.
[0085] An additive is a compound added to a composition which modifies the stability, activity, and/or longevity of one or more components of the composition. In certain embodiments, the composition is an amplification reaction composition. In certain embodiments, an additive inactivates contaminant enzymes, stabilizes protein folding, and/or decreases aggregation. Exemplary additives that may be included in an amplification reaction include, but are not limited to, betaine, formamide, KCl, CaCl 2 , MgOAc, MgCl 2 , NaCl, NH 4 OAc, NaI, Na(CO 3 ) 2 , LiCl, MnOAc, NMP, trehalose, demiethylsulfoxide (“DMSO”), glycerol, ethylene glycol, dithiothreitol (“DTT”), pyrophosphatase (including, but not limited to Thermoplasma acidophilum inorganic pyrophosphatase (“TAP”)), bovine serum albumin (“BSA”), propylene glycol, glycinamide, CHES, Percoll, aurintricarboxylic acid, Tween 20, Tween 21, Tween 40, Tween 60, Tween 85, Brij 30, NP-40, Triton X-100, CHAPS, CHAPSO, Mackernium, LDAO (N-dodecyl-N,N-dimethylamine-N-oxide), Zwittergent 3-10, Xwittergent 3-14, Xwittergent SB 3-16, Empigen, NDSB-20, T4G32, E. Coli SSB, RecA, nicking endonucleases, 7-deazaG, dUTP, anionic detergents, cationic detergents, non-ionic detergents, zwittergent, sterol, osmolytes, cations, and any other chemical, protein, or cofactor that may alter the efficiency of amplification. In certain embodiments, two or more additives are included in an amplification reaction. Additives may be optionally added to improve selectivity of primer annealing provided the additives do not interfere with the activity of RNase H.
[0086] As used herein, an “amplifying polymerase activity” or “amplifying activity” refers to the enzymatic activity associated with nucleic acid amplification such as the activity associated with thermostable DNA polymerases.
[0087] As used herein, the term “thermostable,” as applied to an enzyme, refers to an enzyme that retains its biological activity at elevated temperatures (e. g., at 55° C. or higher), or retains its biological activity following repeated cycles of heating and cooling. Thermostable polynucleotide polymerases find particular use in PCR amplification reactions.
[0088] As used herein, a “thermostable polymerase” is an enzyme that is relatively stable to heat and eliminates the need to add enzyme prior to each PCR cycle. Non-limiting examples of thermostable polymerases may include polymerases isolated from the thermophilic bacteria Thermus aquaticus (Taq polymerase), Thermus thermophilus (Tth polymerase), Thermococcus litoralis (Tli or VENT polymerase), Pyrococcus furiosus (Pfu or DEEPVENT polymerase), Pyrococcus woosii (Pwo polymerase) and other Pyrococcus species, Bacillus stearothermophilus (Bst polymerase), Sulfolobus acidocaldarius (Sac polymerase), Thermoplasma acidophilum (Tac polymerase), Thermus rubber (Tru polymerase), Thermus brockianus (DYNAZYME polymerase), Thermotoga neapolitana (Tne polymerase), Thermotoga maritime (Tma) and other species of the Thermotoga genus (Tsp polymerase), and Methanobacterium thermoautotrophicum (Mth polymerase). The PCR reaction may contain more than one thermostable polymerase enzyme with complementary properties leading to more efficient amplification of target sequences. For example, a nucleotide polymerase with high processivity (the ability to copy large nucleotide segments) may be complemented with another nucleotide polymerase with proofreading capabilities (the ability to correct mistakes during elongation of target nucleic acid sequence), thus creating a PCR reaction that can copy a long target sequence with high fidelity. The thermostable polymerase may be used in its wild type form. Alternatively, the polymerase may be modified to contain a fragment of the enzyme or to contain a mutation that provides beneficial properties to facilitate the PCR reaction. In one embodiment, the thermostable polymerase may be Taq polymerase. Many variants of Taq polymerase with enhanced properties are known and include AmpliTaq, AmpliTaq Stoffel fragment, SuperTaq, SuperTaq plus, LA Taq, LApro Taq, and EX Taq.
Reverse Transcriptase—PCR Amplification of a Salmonella RNA Target Nucleic Acid Sequence
[0089] One of the most widely used techniques to study gene expression exploits first-strand cDNA for mRNA sequence(s) as template for amplification by the PCR. This method, often referred to as RT-PCR or reverse transcriptase-PCR, exploits the high sensitivity and specificity of the PCR process and is widely used for detection and quantification of RNA.
[0090] As used herein, “reverse transcriptase activity” refers to the activity associated with RNA-dependent DNA polymerases that catalyze the synthesis of a complementary DNA strand or cDNA from a single stranded RNA template.
[0091] The reverse transcriptase-PCR procedure, carried out as either an end-point or real-time assay, involves two separate molecular syntheses: (i) the synthesis of cDNA from an RNA template; and (ii) the replication of the newly synthesized cDNA through PCR amplification. To attempt to address the technical problems often associated with reverse transcriptase-PCR, a number of protocols have been developed taking into account the three basic steps of the procedure: (a) the denaturation of RNA and the hybridization of reverse primer; (b) the synthesis of cDNA; and (c) PCR amplification. In the so called “uncoupled” reverse transcriptase-PCR procedure (e.g., two step reverse transcriptase-PCR), reverse transcription is performed as an independent step using the optimal buffer condition for reverse transcriptase activity. Following cDNA synthesis, the reaction is diluted to decrease MgCl 2 , and deoxyribonucleoside triphosphate (dNTP) concentrations to conditions optimal for Taq DNA Polymerase activity, and PCR is carried out according to standard conditions (see U.S. Pat. Nos. 4,683,195 and 4,683,202). By contrast, “coupled” reverse transcriptase PCR methods use a common buffer for reverse transcriptase and Taq DNA Polymerase activities. In one version, the annealing of reverse primer is a separate step preceding the addition of enzymes, which are then added to the single reaction vessel. In another version, the reverse transcriptase activity is a component of the thermostable Tth DNA polymerase. Annealing and cDNA synthesis are performed in the presence of Mn 2+ then PCR is carried out in the presence of Mg 2+ after the removal of Mn 2+ by a chelating agent. Finally, the “continuous” method (e.g., one step reverse transcriptase-PCR) integrates the three reverse transcriptase-PCR steps into a single continuous reaction that avoids the opening of the reaction tube for component or enzyme addition. Continuous reverse transcriptase-PCR has been described as a single enzyme system using the reverse transcriptase activity of thermostable Taq DNA Polymerase and Tth polymerase and as a two enzyme system using AMV reverse transcriptase and Taq DNA Polymerase wherein the initial 65° C. An RNA denaturation step can be omitted.
[0092] The first step in real-time reverse-transcription PCR is to generate the complementary DNA strand using one of the template specific DNA primers. In traditional PCR reactions this product is denatured, the second template specific primer binds to the cDNA, and is extended to form duplex DNA. This product is amplified in subsequent rounds of temperature cycling. To maintain the highest sensitivity it is important that the RNA not be degraded prior to synthesis of cDNA. The presence of RNase H in the reaction buffer will cause unwanted degradation of the RNA:DNA hybrid formed in the first step of the process because it can serve as a substrate for the enzyme. There are two major methods to combat this issue. One is to physically separate the RNase H from the rest of the reverse-transcription reaction using a barrier such as wax that will melt during the initial high temperature DNA denaturation step. A second method is to modify the RNase H such that it is inactive at the reverse-transcription temperature, typically 45-55° C. Several methods are known in the art, including reaction of RNase H with an antibody, or reversible chemical modification. For example, a hot start RNase H activity as used herein can be an RNase H with a reversible chemical modification produced after reaction of the RNase H with cis-aconitic anhydride under alkaline conditions. When the modified enzyme is used in a reaction with a Tris based buffer and the temperature is raised to 95° C. the pH of the solution drops and RNase H activity is restored. This method allows for the inclusion of RNase H in the reaction mixture prior to the initiation of reverse transcription.
[0093] Additional examples of RNase H enzymes and hot start RNase H enzymes that can be employed in the invention are described in U.S. Patent Application No. 2009/0325169 to Walder et al.
[0094] One step reverse transcriptase-PCR provides several advantages over uncoupled reverse transcriptase-PCR. One step reverse transcriptase-PCR requires less handling of the reaction mixture reagents and nucleic acid products than uncoupled reverse transcriptase-PCR (e.g., opening of the reaction tube for component or enzyme addition in between the two reaction steps), and is therefore less labor intensive, reducing the required number of person hours. One step reverse transcriptase-PCR also requires less sample, and reduces the risk of contamination. The sensitivity and specificity of one-step reverse transcriptase-PCR has proven well suited for studying expression levels of one to several genes in a given sample or the detection of pathogen RNA. Typically, this procedure has been limited to use of gene-specific primers to initiate cDNA synthesis.
[0095] The ability to measure the kinetics of a PCR reaction by real-time detection in combination with these reverse transcriptase-PCR techniques has enabled accurate and precise determination of RNA copy number with high sensitivity. This has become possible by detecting the reverse transcriptase-PCR product through fluorescence monitoring and measurement of PCR product during the amplification process by fluorescent dual-labeled hybridization probe technologies, such as the 5′ fluorogenic nuclease assay (“Taq-Man”) or endonuclease assay (“CataCleave”), discussed below.
Real-Time PCR of a Salmonella Target Nucleic Acid Sequence Using a CataCleave Probe
[0096] Post-amplification amplicon detection has been developed to monitor amplification during the PCR process. These methods typically employ fluorescently labeled probes that bind to the newly synthesized DNA or dyes whose fluorescence emission is increased when intercalated into double stranded DNA.
[0097] The probes are generally designed so that donor emission is quenched in the absence of target by fluorescence resonance energy transfer (FRET) between two chromophores. The donor chromophore, in its excited state, may transfer energy to an acceptor chromophore when the pair is in close proximity. This transfer is always non-radiative and occurs through dipole-dipole coupling. Any process that sufficiently increases the distance between the chromophores will decrease FRET efficiency such that the donor chromophore emission can be detected radiatively. Common donor chromophores include FAM, TAMRA, VIC, JOE, Cy3, Cy5, and Texas Red. Acceptor chromophores are chosen so that their excitation spectra overlap with the emission spectrum of the donor. An example of such a pair is FAM-TAMRA. There are also non fluorescent acceptors that will quench a wide range of donors. Other examples of appropriate donor-acceptor FRET pairs will be known to those skilled in the art.
[0098] Common examples of FRET probes that can be used for real-time detection of PCR include molecular beacons, TaqMan probes (e.g., U.S. Pat. Nos. 5,210,015 and 5,487,972), and CataCleave probes (e.g., U.S. Pat. No. 5,763,181). The molecular beacon is a single stranded oligonucleotide designed so that in the unbound state the probe forms a secondary structure where the donor and acceptor chromophores are in close proximity and donor emission is reduced. At the proper reaction temperature, the beacon unfolds and specifically binds to the amplicon. Once unfolded the distance between the donor and acceptor chromophores increases such that FRET is reversed and donor emission can be monitored using specialized instrumentation. TaqMan and CataCleave technologies differ from the molecular beacon in that the FRET probes employed are cleaved such that the donor and acceptor chromophores become sufficiently separated to reverse FRET.
[0099] TaqMan technology employs a single stranded oligonucleotide probe that is labeled at the 5′ end with a donor chromophore and at the 3′ end with an acceptor chromophore. The DNA polymerase used for amplification must contain a 5′→3′ exonuclease activity. The TaqMan probe binds to one strand of the amplicon at the same time that the primer binds. As the DNA polymerase extends the primer the polymerase will eventually encounter the bound TaqMan probe. At this time the exonuclease activity of the polymerase will sequentially degrade the TaqMan probe starting at the 5′ end. As the probe is digested the mononucleotides comprising the probe are released into the reaction buffer. The donor diffuses away from the acceptor and FRET is reversed. Emission from the donor is monitored to identify probe cleavage. Because of the way TaqMan works a specific amplicon can be detected only once for every cycle of PCR. Extension of the primer through the TaqMan target site generates a double stranded product that prevents further binding of TaqMan probes until the amplicon is denatured in the next PCR cycle.
[0100] U.S. Pat. No. 5,763,181, the content of which is incorporated herein by reference, describes another real-time detection method (referred to as “CataCleave”). CataCleave technology differs from TaqMan in that cleavage of the probe is accomplished by a second enzyme that does not have polymerase activity. The CataCleave probe has a sequence within the molecule which is a target of an endonuclease, such as, for example a restriction enzyme or RNase. In one example, the CataCleave probe has a chimeric structure where the 5′ and 3′ ends of the probe are constructed of DNA and the cleavage site contains RNA. The DNA sequence portions of the probe are labeled with a FRET pair either at the ends or internally. The PCR reaction includes an RNase H enzyme that will specifically cleave the RNA sequence portion of a RNA-DNA duplex. After cleavage, the two halves of the probe dissociate from the target amplicon at the reaction temperature and diffuse into the reaction buffer. As the donor and acceptors separate FRET is reversed in the same way as the TaqMan probe and donor emission can be monitored. Cleavage and dissociation regenerates a site for further CataCleave binding. In this way it is possible for a single amplicon to serve as a target or multiple rounds of probe cleavage until the primer is extended through the CataCleave probe binding site.
Labeling of a Salmonella -Specific CataCleave Probe
[0101] The term “probe” as used herein refers to a polynucleotide that comprises a specific portion designed to hybridize in a sequence-specific manner with a complementary region of a specific nucleic acid sequence, e.g., a target nucleic acid sequence. In one embodiment, the oligonucleotide probe is in the range of 15-60 nucleotides in length. More preferably, the oligonucleotide probe is in the range of 18-30 nucleotides in length. The precise sequence and length of an oligonucleotide probe of the invention depends in part on the nature of the target polynucleotide to which it binds. The binding location and length may be varied to achieve appropriate annealing and melting properties for a particular embodiment. Guidance for making such design choices can be found in many of the references describing Taq-man assays or CataCleave, described in U.S. Pat. Nos. 5,763,181, 6,787,304, and 7,112,422, the contents of which contents are incorporated herein by reference in their entirety.
[0102] As used herein, the term “label” or “detectable label” may refer to any label which can be detected by optical or chemical means. For example, in one embodiment, the label or detectable label of a CataCleave probe may comprise a fluorochrome compound that is attached to the probe by covalent or non-covalent means.
[0103] As used herein, the term “fluorochrome” refers to a fluorescent compound that emits light upon excitation by light of a shorter wavelength than the light that is emitted. The term “fluorescent donor” or “fluorescence donor” refers to a fluorochrome that emits light that is measured in the assays described in the present invention. More specifically, a fluorescent donor provides light that is absorbed by a fluorescence acceptor. The term “fluorescent acceptor” or “fluorescence acceptor” refers to either a second fluorochrome or a quenching molecule that absorbs energy emitted from the fluorescence donor. The second fluorochrome absorbs the energy that is emitted from the fluorescence donor and emits light of longer wavelength than the light emitted by the fluorescence donor. The quenching molecule absorbs energy emitted by the fluorescence donor.
[0104] Any luminescent molecule, preferably a fluorochrome and/or fluorescent quencher may be used in the practice of this invention, including, for example, Alexa Fluor 350, Alexa Fluor 430, Alexa Fluor 488, Alexa Fluor 532, Alexa Fluor 546, Alexa Fluor 568, Alexa Fluor 594, Alexa Fluor 633, Alexa Fluor 647, Alexa Fluor 660, Alexa Fluor 680, 7-diethylaminocoumarin-3-carboxylic acid, fluorescein, Oregon Green 488, Oregon Green 514, tetramethylrhodamine, rhodamine X, Texas Red dye, QSY 7, QSY33, Dabcyl, BODIPY FL, BODIPY 630/650, BODIPY 6501665, BODIPY TMR-X, BODIPY TR-X, dialkylaminocoumarin, Cy5.5, Cy5, Cy3.5, Cy3, DTPA(Eu3+)-AMCA and TTHA(Eu3 + )AMCA.
[0105] In one embodiment, the 3′ terminal nucleotide of the oligonucleotide probe is blocked or rendered incapable of extension by a nucleic acid polymerase. Such blocking is conveniently carried out by the attachment of a reporter or quencher molecule to the terminal 3′ position of the probe.
[0106] In one embodiment, reporter molecules are fluorescent organic dyes derivatized for attachment to the terminal 3′ or terminal 5′ ends of the probe via a linking moiety. Preferably, quencher molecules are also organic dyes, which may or may not be fluorescent, depending on the embodiment of the invention. For example, in a preferred embodiment of the invention, the quencher molecule is non-fluorescent. Generally whether the quencher molecule is fluorescent or simply releases the transferred energy from the reporter by non-radiative decay, the absorption band of the quencher should substantially overlap the fluorescent emission band of the reporter molecule. Non-fluorescent quencher molecules that absorb energy from excited reporter molecules, but which do not release the energy radiatively, are referred to in the application as chromogenic molecules.
[0107] Exemplary reporter-quencher pairs may be selected from xanthene dyes, including fluoresceins, and rhodamine dyes. Many suitable forms of these compounds are widely available commercially with substituents on their phenyl moieties which can be used as the site for bonding or as the bonding functionality for attachment to an oligonucleotide. Another group of fluorescent compounds are the naphthylamines, having an amino group in the alpha or beta position. Included among such naphthylamino compounds are 1-dimethylaminonaphthyl-5-sulfonate, 1-anilino-8-naphthalene sulfonate and 2-p-touidinyl6-naphthalene sulfonate. Other dyes include 3-phenyl-7-isocyanatocoumarin, acridines, such as 9-isothiocyanatoacridine and acridine orange; N-(p-(2-benzoxazolyl)phenyl)maleimide; benzoxadiazoles, stilbenes, pyrenes, and the like.
[0108] In one embodiment, reporter and quencher molecules are selected from fluorescein and non-fluorescent quencher dyes.
[0109] There are many linking moieties and methodologies for attaching reporter or quencher molecules to the 5′ or 3′ termini of oligonucleotides, as exemplified by the following references: Eckstein, editor, Oligonucleotides and Analogues: A Practical Approach (IRL Press, Oxford, 1991); Zuckerman et al., Nucleic Acids Research, 15: 5305-5321 (1987) (3′ thiol group on oligonucleotide); Sharma et al., Nucleic Acids Research, 19: 3019 (1991) (3′ sulfhydryl); Giusti et al., PCR Methods and Applications, 2: 223-227 (1993) and Fung et al., U.S. Pat. No. 4,757,141 (5′ phosphoamino group via Aminolink. II available from Applied Biosystems, Foster City, Calif.) Stabinsky, U.S. Pat. No. 4,739,044 (3′ aminoalkylphosphoryl group); Agrawal et al., Tetrahedron Letters, 31: 1543-1546 (1990) (attachment via phosphoramidate linkages); Sproat et al., Nucleic Acids Research, 15: 4837 (1987) (5′ mercapto group); Nelson et al., Nucleic Acids Research, 17: 7187-7194 (1989) (3′ amino group); and the like.
[0110] Rhodamine and non-fluorescent quencher dyes are also conveniently attached to the 3′ end of an oligonucleotide at the beginning of solid phase synthesis, e.g., Woo et al., U.S. Pat. No. 5,231,191; and Hobbs, Jr., U.S. Pat. No. 4,997,928.
Attachment of a Salmonella -Specific CataCleave Probe to a Solid Support
[0111] In one embodiment of the invention, the oligonucleotide probe can be attached to a solid support. Different probes may be attached to the solid support and may be used to simultaneously detect different target sequences in a sample. Reporter molecules having different fluorescence wavelengths can be used on the different probes, thus enabling hybridization to the different probes to be separately detected.
[0112] Examples of preferred types of solid supports for immobilization of the oligonucleotide probe include polystyrene, avidin coated polystyrene beads cellulose, nylon, acrylamide gel and activated dextran, controlled pore glass (CPG), glass plates and highly cross-linked polystyrene. These solid supports are preferred for hybridization and diagnostic studies because of their chemical stability, ease of functionalization and well defined surface area. Solid supports such as controlled pore glass (500 Å, 1000 Å) and non-swelling high cross-linked polystyrene (1000 Å) are particularly preferred in view of their compatibility with oligonucleotide synthesis.
[0113] The oligonucleotide probe may be attached to the solid support in a variety of manners. For example, the probe may be attached to the solid support by attachment of the 3′ or 5′ terminal nucleotide of the probe to the solid support. However, the probe may be attached to the solid support by a linker which serves to distance the probe from the solid support. The linker is most preferably at least 30 atoms in length, more preferably at least 50 atoms in length.
[0114] Hybridization of a probe immobilized to a solid support generally requires that the probe be separated from the solid support by at least 30 atoms, more-preferably at least 50 atoms. In order to achieve this separation, the linker generally includes a spacer positioned between the linker and the 3′ nucleoside. For oligonucleotide synthesis, the linker arm is usually attached to the 3′-OH of the 3′ nucleoside by an ester linkage which can be cleaved with basic reagents to free the oligonucleotide from the solid support.
[0115] A wide variety of linkers are known in the art which may be used to attach the oligonucleotide probe to the solid support. The linker may be formed of any compound which does not significantly interfere with the hybridization of the target sequence to the probe attached to the solid support. The linker may be formed of a homopolymeric oligonucleotide which can be readily added on to the linker by automated synthesis. Alternatively, polymers such as functionalized polyethylene glycol can be used as the linker. Such polymers are preferred over homopolymeric oligonucleotides because they do not significantly interfere with the hybridization of probe to the target oligonucleotide. Polyethylene glycol is particularly preferred because it is commercially available, soluble in both organic and aqueous media, easy to functionalize, and is completely stable under oligonucleotide synthesis and post-synthesis conditions.
[0116] The linkages between the solid support, the linker and the probe are preferably not cleaved during removal of base protecting groups under basic conditions at high temperature. Examples of preferred linkages include carbamate and amide linkages. Immobilization of a probe is well known in the art and one skilled in the art may determine the immobilization conditions.
[0117] According to one embodiment of the method, the hybridization probe is immobilized on a solid support. The oligonucleotide probe is contacted with a sample of nucleic acids under conditions favorable for hybridization. The fluorescence signal of the reporter molecule is measured before and after being contacted with the sample. Since the reporter molecule on the probe exhibits a greater fluorescence signal when hybridized to a target sequence, an increase in the fluorescence signal after the probe is contacted with the sample indicates the hybridization of the probe to target sequences in the sample. In an unhybridized state, the fluorescent label is quenched by the quencher. On hybridization to the target, the fluorescent label is separated from the quencher resulting in fluorescence.
[0118] Immobilization of the hybridization probe to the solid support also enables the target sequence hybridized to the probe to be readily isolated from the sample. In later steps, the isolated target sequence may be separated from the solid support and processed (e.g., purified, amplified) according to methods well known in the art depending on the particular needs of the researcher.
Real-Time Detection of Salmonella Target Nucleic Acid Sequences Using a CataCleave Probe
[0119] The labeled oligonucleotide probe may be used as a probe for the real-time detection of Salmonella target nucleic acid sequence in a sample.
[0120] A CataCleave oligonucleotide probe is first synthesized with DNA and RNA sequences that are complimentary to sequences found within a PCR amplicon comprising a selected Salmonella target sequence. In one embodiment, the probe is labeled with a FRET pair, for example, a fluorescein molecule at one end of the probe and a non-fluorescent quencher molecule at the other end. Hence, upon hybridization of the probe with the PCR amplicon, a RNA:DNA heteroduplex forms that can be cleaved by an RNase H activity.
[0121] RNase H hydrolyzes RNA in RNA-DNA hybrids. This enzyme was first identified in calf thymus but has subsequently been described in a variety of organisms. RNase H activity appears to be ubiquitous in eukaryotes and bacteria. Although RNase Hs constitute a family of proteins of varying molecular weight and nucleolytic activity, substrate requirements appear to be similar for the various isotypes. For example, most RNase H's studied to date function as endonucleases and requiring divalent cations (e.g., Mg 2+ , Mn 2+ ) to produce cleavage products with 5′ phosphate and 3′ hydroxyl termini.
[0122] RNase HI from E.coli is the best-characterized member of the RNase H family. In addition to RNase HI, a second E.coli RNase H, RNase HII has been cloned and characterized (Itaya, M., Proc. Natl. Acad. Sci. USA, 1990, 87, 8587-8591). It is comprised of 213 amino acids while RNase HI is 155 amino acids long. E. coli RNase HIM displays only 17% homology with E.coli RNase HI. An RNase H cloned from S. typhimurium differed from E.coli RNase HI in only 11 positions and was 155 amino acids in length (Itaya, M. and Kondo K., Nucleic Acids Res., 1991, 19, 4443-4449).
[0123] Proteins that display RNase H activity have also been cloned and purified from a number of viruses, other bacteria and yeast (Wintersberger, U. Pharmac. Ther., 1990, 48, 259-280). In many cases, proteins with RNase H activity appear to be fusion proteins in which RNase H is fused to the amino or carboxy end of another enzyme, often a DNA or RNA polymerase. The RNase H domain has been consistently found to be highly homologous to E.coli RNase HI, but because the other domains vary substantially, the molecular weights and other characteristics of the fusion proteins vary widely.
[0124] In higher eukaryotes two classes of RNase H have been defined based on differences in molecular weight, effects of divalent cations, sensitivity to sulfhydryl agents and immunological cross-reactivity (Busen et al., Eur. J. Biochem., 1977, 74, 203-208). RNase HI enzymes are reported to have molecular weights in the 68-90 kDa range, be activated by either Mn 2+ or Mg 2+ and be insensitive to sulfhydryl agents. In contrast, RNase H II enzymes have been reported to have molecular weights ranging from 31-45 kDa, to require Mg 2+ to be highly sensitive to sulfhydryl agents and to be inhibited by Mn 2+ (Busen, W., and Hausen, P., Eur. J. Biochem., 1975, 52, 179-190; Kane, C. M., Biochemistry, 1988, 27, 3187-3196; Busen, W., J. Biol. Chem., 1982, 257, 7106-7108.).
[0125] An enzyme with RNase HII characteristics has been purified to near homogeneity from human placenta (Frank et al., Nucleic Acids Res., 1994, 22, 5247-5254). This protein is reported to have a molecular weight of approximately 33 kDa and be active in a pH range of 6.5-10, with a pH optimum of 8.5-9. The enzyme is reported to require Mg 2+ and be inhibited by Mn 2+ and n-ethyl maleimide. The products of cleavage reactions have 3′ hydroxyl and 5′ phosphate termini.
[0126] According to an embodiment, real-time nucleic acid amplification is performed on a target polynucleotide in the presence of a thermostable nucleic acid polymerase, an RNase H activity, a pair of PCR amplification primers capable of hybridizing to the Salmonella target polynucleotide, and the labeled CataCleave oligonucleotide probe. During the real-time PCR reaction, cleavage of the probe by RNase H leads to the separation of the fluorescent donor from the fluorescent quencher and results in the real-time increase in fluorescence of the probe corresponding to the real-time detection of Salmonella target DNA sequences in the sample.
[0127] In certain embodiments, the real-time nucleic acid amplification permits the real-time detection of a single target DNA molecule in less than about 40 PCR amplification cycles.
Kits
[0128] The disclosure herein also provides for a kit format which comprises a package unit having one or more reagents for the real-time detection of Salmonella target nucleic acid sequences in a sample. The kit may also contain one or more of the following items: buffers, instructions, and positive or negative controls. Kits may include containers of reagents mixed together in suitable proportions for performing the methods described herein. Reagent containers preferably contain reagents in unit quantities that obviate measuring steps when performing the subject methods.
[0129] The kit may contain a lysis reagent comprising a buffer with a pH of about 6 to about 9, a zwitterionic detergent at a concentration of about 0.125% to about 2%, and an azide at a concentration of about 0.3 to about 2.5 mg/ml. For the lysis of gram positive bacteria, the kit may include a protease, for example, 100 mg of lyophilized proteinase K and an aliquot of a buffer solution for the reconstitution of the proteinase K solution. In one embodiment, the 1× lysis reagent contains 12.5 mM Tris acetate (pH 8.0) or Tris-HCl (pH 8.0) or HEPES (pH=7.8), 0.25% (w/v) CHAPS, and 0.3125 mg/ml sodium azide.
[0130] Kits may also contain reagents for real-time PCR including, but not limited to, a thermostable polymerase, thermostable RNase H, primers selected to amplify a Samonella nucleic acid target sequence and a labeled CataCleave oligonucleotide probe that anneals to the real-time PCR product and allow for the detection of Salmonella target nucleic acid sequences according to the methodology described herein. Kits may comprise reagents for the detection of two or more Salmonella target nucleic acid sequences. Kit reagents may also include reagents for RT-PCR analysis where applicable.
[0131] In certain embodiments, the amplification primer pair has the sequence of SEQ ID NOs 1 and 2.
[0132] In other embodiments, the CataCleave oligonucleotide probe has the sequence of SEQ ID NO: 3.
EXAMPLES
[0133] The present invention will now be illustrated by the following examples, which are not to be considered limiting in any way.
Example 1
Lysis of Salmonella
[0134] 5 μL of ground beef enrichment (spiked with Salmonella ) are diluted into 42.5 μL of lysis buffer containing 2.5 μl proteinase K (20.1 mg/ml). The samples are incubated at 55° C. for 15 minutes and then heated to 95° C. for 10 minutes prior to cooling. 2 μl of lysate is then added to each PCR-CataCleave reaction.
Example 2
Real-Time Detection of the Gram Negative Pathogen Salmonella INVA Gene Sequences in the Presence of Different Lysis Reagents
[0135] Eight Lysis Buffers were Tested:
[0136] 1. CZ1: 1% CHAPS, 1 mg/mL sodium azide, 20 mM HEPES-KOH (pH 8)
[0137] 2. CZ2: 2% CHAPS, 1 mg/mL sodium azide, 20 mM HEPES-KOH (pH 8)
[0138] 3. CZ3: 0.5% CHAPS, 1 mg/mL sodium azide, 20 mM HEPES-KOH (pH 8)
[0139] 4. CZ4: 1% CHAPS, 0.5 mg/mL sodium azide, 20 mM HEPES-KOH (pH 8)
[0140] 5. CZ5: 1% CHAPS, 2.5 mg/mL sodium azide 20 mM HEPES-KOH (pH 8)
[0141] 6. CZ6: 1% CHAPS, 1 mg/mL sodium azide, 20 mM HEPES-KOH (pH 8)
[0142] 7. CZ7: 1% CHAPS, 1 mg/mL sodium azide, 100 mM HEPES-KOH (pH 8)
[0143] 8. 0.125 TZ (1× TZ: 2% Triton-X, 5 mg/ml sodium azide, 0.2 M Tris pH=8)
[0144] Each reaction mix contained amplification buffer (32 mM HEPES ((4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid)-KOH, pH 7.8, 100 mM potassium acetate, 4 mM magnesium acetate, 0.11% bovine serum albumin, 1% dimethylsulfoxide), 800 nM Salmonella -Forward primer (SEQ ID NO. 1), 800 nM Salmonella -Reverse primer (SEQ ID NO. 2), 200 nM Salmonella CataCleave probe (SEQ ID NO. 3), dUTP/NTP mix (80 μM dGTP, dCTP, dATP and 160 μM dUTP), 2.5 Units Thermus aquaticus DNA polymerase, 1 Unit Pyrococcus furiosis RNase HII, and 0.1 Unit Uracil-N-Glycosylase and lysate.
[0000]
Component
μl/25 μl rxn
10X ICAN Buffer
2.5
1
1
1
Fermentas dN/UTP (2/4 mM)
1
0.5
0.1
RNaseH II (undiluted)
0.2
Lysate
2
Water
15.70
[0145] The Salmonella Forward and Reverse primers amplify a 180 base pair fragment contained within the Salmonella invasion gene (invA).
[0146] The sequences of the primers and probes were as follows:
[0000] Salmonella -Forward primer: (SEQ ID NO: 1) 5′-TCGTCATTCCATTACCTACC Salmonella -Reverse primer: (SEQ ID NO: 2) 5′-TACTGATCGATAATGCCAGACGAA Salmonella CataCleave Probe: (SEQ ID NO: 3) 5′-/FAM/CGATCAGrGrArArATCAACCAG/IABFQ),
where lowercase “r” denotes RNA bases (i.e. rG is riboguanosine)
[0147] Abbreviations: FAM: 6-Carboxyfluorescein; IABHQ: Iowa Black Hole Quencher for short wavelength emission from Integrated DNA Technologies (Coralville, Iowa).
[0148] The reaction were run on a Roche Lightcycler 480 using the following cycling protocol: 37° C. for 10 minutes; 95° C. for 10 minutes; then 50 cycles of amplification; 95° C. for 15 seconds, 60° C. for 20 seconds.
[0149] FAM emission was monitored during the 60° C. step.
Results:
[0150]
[0000]
Cp values
Lysis
Sample
Sample
Sample
Sample
Std.
solution
1
2
3
4
Average
Dev.
CZ1
22.75
24.68
27.59
24.31
24.83
2.02
CZ2
24.84
22.5
22.65
22.44
23.11
1.16
CZ3
21.7
21.32
21.59
21.24
21.46
0.22
CZ4
21.78
21.25
22.21
21.63
21.72
0.40
CZ5
20:99
20.78
22.74
20.46
21.24
1.02
CZ6
22.5
2219
21.64
20.87
21 80
0.71
CZ7
22.33
21.3
21.38
23.47
22.12
1.01
0.125 TZ
24.69
24.13
22.89
23.53
23.81
0.77
[0151] The raw data from the CataCleave-PCR reactions are depicted as an output graph in FIG. 3A . The data show CZ5 with a composition of CZ5: 1% CHAPS, 2.5 mg/mL sodium azide 20 mM HEPES-KOH (pH 8) was the best lysate reagent for Salmonella.
Example 3
Real-Time Detection of the Gram Positive Pathogen Listeria invA Gene Sequences in the Presence of Different Lysis Reagents
1) Control CataCleave PCR in the Presence of Different Concentrations of Lysis Reagent
[0152] A control CataCleave PCR was first tested on purified target DNA resuspended in following lysis reagent concentrations:
1× ZAC, 0.5× ZAC, 0.25× ZAC, 0.125× ZAC and 0.125× TZ lysis reagent. (1× ZAC contains 100 mM Tris-acetate (pH 8.0), 1% (w/v) CHAPS, 2.5 mg/mL sodium azide)
[0155] Five microliters of ground beef enrichment (spiked with Listeria ) was first added to 42.5 μl of lysis agent and 2.5 μl proteinase K (20 mg/ml) and incubated at 55° C. for 15 minutes. After inactivation at 95° C. for 10 minutes, 2 μl of the lysate was added to each reaction mix containing 1× ICAN amplification buffer (32 mM HEPES-KOH, pH 7.8; 4 mM magnesium acetate; 1% DMSO; and, 0.11% BSA), 400 nM LmonC3-Forward primer (SEQ ID NO. 5), 400 nM LmonC3-Reverse primer (SEQ ID NO. 6), 200 nM CataCleave probe (SEQ ID NO. 7), dUTP/NTP mix (80 μM dGTP, dCTP, dATP and 160 μM dUTP), 2.5 Units Thermus aquaticus DNA polymerase, 1 Unit Pyrococcus furiosis RNase HII, and 0.1 unit uracil-N-glycosylase (UNG).
[0000]
Component
μl/25 μl rxn
10X ICAN Buffer
2.5
Forward primer (20
1
1
1
Fermentas dN/UTP (2/4
1
Taq polymerase (5
0.5
0.1
RNaseH II (undiluted)
0.2
lysate
2
Water
15.70
[0000] Lmon C3F: (SEQ ID NO.: 5) ACGAGTAACGGGACAAATGC Lmon C3R: (SEQ ID NO.: 6) TCCCTAATCTATCCGCCTGA Lmon CC C3B: (SEQ ID NO.: 7) 5′-/FAM/-CGAATGTAArCAGACACGGTCTCA/IABFQ/,
whereas lowercase “r” denotes RNA bases (i.e., rC is ribocytidine)
[0156] The reactions were run on a Roche Lightcycler 480 using the following cycling protocol: 37° C. for 10 minutes; 95° C. for 10 minutes; then 50 cycles of amplification; 95° C. for 15 seconds, 60° C. for 20 seconds. FAM emission was monitored during the 60° C. step.
Results
[0157]
[0000]
Cp values
Lysis
Sample
Sample
Sample
Standard
Number
Solution
1
2
3
Average
Dev.
1
1x ZAC
19.57
19.67
19.58
19.61
0.06
2
0.5x ZAC
19.58
19.53
19.57
19.56
0.03
3
0.25x ZAC
20.52
20.3
20.5
20.44
0.12
4
0.125x ZAC
20.87
20.83
20.81
20.84
0.03
5
0.125x TZ
20.38
20.33
20.37
20.36
0.03
[0158] The raw data from the CataCleave-PCR reactions are depicted as an output graph in FIG. 3B . The results show that the lysis reagent does not inhibit the PCR CataCleave reaction.
2) CataCleave PCR in the Presence of Different Concentrations of Lysis Reagent
[0159] 5 μL of ground beef enrichment (spiked with Listeria ) were diluted into 42.5 μL of lysis agent containing 2.5 μl proteinase K (20.1 mg/ml). The samples are incubated at 55° C. for 15 minutes and then heated to 95° C. for 10 minutes and then cooled.
[0160] 17.7 μl of lysate was then added to each reaction mix containing amplification buffer 1× ICAN buffer, 400 nM LmonC3-forward primer (SEQ ID NO. 5), 400 nM LmonC3-reverse primer (SEQ ID NO. 6), 200 nM CataCleave probe (SEQ ID NO. 7), dUTP/NTP mix (80 μM dGTP, dCTP, dATP and 160 μM dUTP), 2.5 units Thermus aquaticus DNA polymerase, 1 unit Pyrococcus furiosis RNase HII, and 0.1 unit uracil-N-glycosylase (UNG).
[0000] Component μl/25 μl rxn 10X ICAN Buffer 2.5 Forward primer 1 Reverse primer (20 1 1 Fermentas dN/UTP 1 Taq polymerase (5 0.5 0.1 RNaseH II 0.2 lysate 17.7
The reactions were run on a Roche Lightcycler 480 using the following cycling protocol: 37° C. for 10 minutes, 95° C. for 10 minutes, then 50 cycles of amplification, 95° C. for 15 seconds, 60° C. for 20 seconds. FAM emission was monitored during the 60° C. step.
Results
[0161]
[0000]
Cp values
Column
Lysis Solution
Sample 1
Sample 2
Average
1
1x
ZAC
NONE
NONE
NONE
2
0.5x
ZAC.
NONE
NONE
NONE
3
0.425x
ZAC
28.96
28.76
28.86
4
0.125x
ZAC
20.35
20.29
20.32
5
0.125x
TZ
20.82
20.69
20.76
[0162] The raw data from the CataCleave-PCR reactions are depicted as an output graph in FIG. 4 .
[0163] The lysis reagent 0.125× ZAC is shown to be optimal for the combined lysis and PCR CataCleave assay for the detection of the invA Listeria gene. The results also show that the 0.125× ZAC lysis reagent is superior to 0.125× TZ lysis agent (A. Abolmaaty, C. Vu, J. Oliver and R. E. Levin. 2000. Microbio. 101:181-189).
[0164] An overnight culture of L. monocytogenes cells were diluted and lysed in 0.125× ZAC with 1 mg/ml proteinase K, and 2 μl of the resulting lysate was added to each reaction mix containing 1× ICAN amplification buffer, 400 nM LmonC3-forward primer (SEQ ID NO. 5), 400 nM LmonC3-reverse primer (SEQ ID NO. 6), 200 nM CataCleave probe (SEQ ID NO. 7), dUTP/NTP mix (80 μM dGTP, dCTP, dATP and 160 μM dUTP), 2.5 units Thermus aquaticus DNA polymerase, 1 unit Pyrococcus furiosis RNase HII, and 0.1 unit uracil-N-glycosylase (UNG).
[0165] The raw data from the CataCleave-PCR reactions are depicted as an output graph in FIG. 5 .
[0166] The results shown in FIG. 5 demonstrate that the assay was able to detect 1 cfu, or one genomic copy of L. monocytogenes.
[0167] Any patent, patent application, publication, or other disclosure material identified in the specification is hereby incorporated by reference herein in its entirety. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein is only incorporated to the extent that no conflict arises between that incorporated material and the present disclosure material. | 4y
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the priority of European Patent Application, Serial No. 11174997, filed Jul. 22, 2011, pursuant to 35 U.S.C. 119(a)-(d), the content of which is incorporated herein by reference in its entirety as if fully set forth herein.
BACKGROUND OF THE INVENTION
The present invention relates to a squirrel-cage rotor of an asynchronous machine, and to a method for producing such a squirrel-cage rotor.
The following discussion of related art is provided to assist the reader in understanding the advantages of the invention, and is not to be construed as an admission that this related art is prior art to this invention.
Squirrel-cage rotors of asynchronous machines, also referred to as cage rotors, are exposed to the risk, particularly at high rotational speeds, of their short-circuit rings, which are arranged on the axial ends of the laminated core, bending or even breaking on account of centrifugal forces. For example, U.S. Pat. No. 5,719,457 proposes to control centrifugal forces in the region of the short-circuit rings, which is axially distanced from a laminated core, by pushing shrink rings over the short-circuit rings.
DE 199 27 279 A1 proposes interference fit assemblies of a short-circuit ring which is axially distanced from the laminated core to absorb the centrifugal forces of the short-circuit ring.
DE 10 2005 030 798 A1 discloses a rotor of an asynchronous machine, having short-circuit rings available directly on the front faces of a laminated core, wherein the laminated core has grooves for receiving short-circuit rods, wherein the short-circuit rods on the respective front faces are connected by the short-circuit ring and wherein additional profiled sheets exist in the region of the short-circuit ring, which are used to pack the laminated core and to absorb the centrifugal forces of the short-circuit ring.
Common to all conventional solutions is the fact that they are relatively complicated and thus costly in terms of their realization. Shrink rings or interference fit assemblies cause mechanical stresses in the affected components, which, as experience has shown, come into play after a period of operation and thus cause geometric changes in the rotor which negatively affect the original smoothness of the squirrel-cage rotor.
It would therefore be desirable and advantageous to provide an improved squirrel-cage rotor for an asynchronous machine to obviate prior art shortcomings and to be applicable for high rotational speeds, while yet being simple in structure and effectively ensuring absorption of forces occurring particularly in the region of the short-circuit ring at high rotational speeds of the squirrel-cage rotor.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, a squirrel-cage rotor of an asynchronous machine includes a laminated core having grooves and positioned in fixed rotative engagement on a shaft, a squirrel cage including short-circuit rods which are received in the grooves and have opposite front faces, and short-circuit rings which connect the short-circuit rods on the front faces, shrink rings respectively surrounding the short-circuit rings at least radially outside and resting on the shaft, and a pressure-resistant hardenable plastic provided in a gap between the short-circuit rings and the shrink rings.
According to another aspect of the present invention, a method for producing a squirrel-cage rotor of an asynchronous machine includes packaging or punch packaging a laminated core, positioning a squirrel cage in the laminated core, shrink fitting the laminated core on a shaft, axially attaching shrink rings on front faces of the squirrel cage, and injecting hardenable pressure-resistant plastic into a gap between the shrink ring and a short-circuit ring of the squirrel cage.
In order to absorb centrifugal forces of the squirrel-cage rotor at high rotational speeds, e.g. of greater than 4000 rpm, in particular of the short-circuit ring, a shrink ring is now provided on the front faces in accordance with the invention. The shrink ring is axially inserted onto the shaft and radially surrounding the short-circuit ring at least on its surface facing a stator. The centrifugal force stress of the short-circuit ring and the laminations can therefore now be considerably reduced in the region of the short-circuit ring.
On account of the necessary measuring accuracies, the gap between the shrink ring and the short-circuit ring is now provided in accordance with the invention with a hardenable pressure-resistant plastic material. After the positioning of the shrink rings onto the short-circuit rings, this plastic is introduced and hardened via an injection opening provided especially on the shrink rings or via the gap itself into the gap between the short-circuit ring and the shrink ring.
The production of the squirrel-cage rotor is therefore advantageous as follows. Both the squirrel-cage rotor and also the shrink ring do not have to be processed exactly to size in order to effectively compensate for forces occurring during operation. No mechanical stresses are therefore introduced into these components which reduce and/or come into play over the course of time and as a result negatively affect the smoothness of the squirrel-cage rotor.
The hardened plastic causes the forces to be passed on directly from the short-circuit ring to the shrink ring, as if the short-circuit ring and shrink ring were custom-built.
In accordance with the invention, the short-circuit ring therefore has to be cast less accurately to size, and also the shrink ring, particularly with the segment which surrounds the short-circuit ring, in particular has to be embodied less accurately to size. As a result, imbalances possibly occurring in the squirrel-cage rotor can be compensated for by suitable means on the front faces of the short-circuit ring and/or of the shrink ring.
Additional material, for instance in the form of balancing cams, which is added to a predeterminable radius of the short-circuit ring or of the shrink ring, is particularly suitable here.
Similarly, material can also be removed and/or taken off at the above-cited points.
The centrifugal forces are now passed on from the short-circuit ring via the hardened plastic to the enclosure of the shrink ring and absorbed there so that no radial outwards load is placed on the short-circuit ring.
The enclosing surface is ensured by a bowl-shaped inner surface of the shrink ring in the region of the short-circuit ring. The enclosing surface can however also be embodied as a supporting ring, which supports the short-circuit ring only on one side, in particular the radially exterior side, which faces a stator. The decisive factor here is that at least the gap between the short-circuit ring and the radial enclosing surface is provided with hardenable plastic.
According to another advantageous feature of the present invention, both the short-circuit ring and also the plastic and in particular the shrink ring can have the same thermal expansion coefficients. Unnecessary material stresses within the arrangement are thus prevented.
The production method of a squirrel-cage rotor is simplified in accordance with the invention in that the previously simply die-cast squirrel-cage rotor is now provided with a shrink ring on the two front faces, which does not have to be processed and/or pressed and/or shrunk precisely to the size and in a custom-fit manner.
The inevitable gap arising between the inner surface of the shrink ring and the surface of the short-circuit ring is now filled in accordance with the invention with a hardenable pressure-resistant plastic.
The retaining forces of the shrink ring retroact directly on the short-circuit ring, which during operation of the asynchronous machine, attempts to extend radially on account of the developing centrifugal forces.
The plastic can enter the gap between the inner surface of the shrink ring and the surface of the short-circuit ring here in different ways.
The plastic is put into the gap by way of an assembly apparatus, which prevents plastic from escaping at the edges of the shrink ring. The gap can therefore also be filled with plastic at a predeterminable pressure, which prevents cavities in the gap. The centrifugal force compensation is thus ensured in any event.
A further variant is to provide the plastic with a predeterminable layer thickness prior to assembly of the shrink ring onto the short-circuit ring, e.g. on the inner surface of the shrink ring. By placing and positioning the shrink ring on the short-circuit ring, the extra plastic oozes out of the gap and is removed prior to hardening of the plastic.
The plastic is hardened for instance by means of a temperature effect. In this way either the whole squirrel-cage rotor or only the short-circuit ring provided with the shrink rings and the plastic are exposed to a heat treatment which can be varied in terms of time and temperature.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
FIG. 1 shows a longitudinal section of an asynchronous machine;
FIG. 2 shows a detailed view of a short-circuit ring; and
FIGS. 3 to 6 show embodiments of the shrink ring.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Throughout all the figures, same or corresponding elements may generally be indicated by same reference numerals. These depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way. It should also be understood that the figures are not necessarily to scale and that the embodiments are sometimes illustrated by graphic symbols, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted.
Turning now to the drawing, and in particular to FIG. 1 , there is shown a basic longitudinal section of an asynchronous machine 1 in a housing 2 , which has a stator laminated core 3 , into which a winding (not shown in more detail) is placed, which embodies coil ends 4 on the front faces of the stator laminated core 3 . The stator laminated core 3 surrounds a stator hole. A rotor 5 , which is embodied as a squirrel-cage rotor is located radially inside the stator hole. The rotor 5 is constructed from laminated sheets, which are connected to a shaft 12 in a rotatably fixed manner. The shaft 12 is mounted in the housing 2 .
Short-circuit rods 6 , which are electrically conductively connected to a short-circuit ring 7 directly on the front face of the rotor, are located in grooves (not shown in more detail) of the laminated core of the rotor 5 formed from laminations. In particular, short-circuit rods 6 and short-circuit ring 7 form a single part produced in the die casting method, a squirrel cage.
The invention is however also suited to squirrel-cage rotors, in which short-circuit rods 6 and short-circuit rings 7 are welded or soldered to one another.
Similarly, the invention is also suited to a rotor 5 , in which the short-circuit rings 7 are at a distance from the front faces of the laminated core of the rotor 5 .
A shrink ring 8 encompassing the short-circuit ring 7 is located on the front faces of the rotor 5 in each instance. In this embodiment according to FIG. 1 , the short-circuit ring 7 is in this case surrounded on three sides by the shrink ring and delimited on one side by the laminated core of the rotor 5 .
A gap 9 , which is filled with a pressure-resistant hardenable plastic is located between the shrink ring 8 and the short-circuit ring 7 . This takes place for instance by way of special openings of the shrink ring 8 , which are not shown in further detail. The shrink ring 8 is positioned by a stop 14 of the shaft 12 on the left side, whereas the ring is positioned by a shaft projection 13 on the right side of the rotor 5 .
The position of the shrink rings 8 and also the laminated core of the rotor 5 is defined by its position with respect to the shaft 12 . Measuring accuracy of these parts is thus only needed in respect of the shaft 12 . Measuring accuracy of the inner surface of the shrink ring 8 relative to the short-circuit ring 7 is only needed to a limited extent. The gap 9 therefore has various widths, which are however filled by the pressure-resistant hardenable plastic and are thus non-critical.
According to FIG. 2 the centrifugal forces F Z of the short-circuit ring 7 are thus absorbed during operation of the asynchronous machine.
The laminated core of the rotor 5 is moved here for production purposes from the right side onto the shaft 12 and is connected thereto in a non-rotatable manner. This is done for instance by means of a shrink-on process. In this case the laminated core of the rotor 5 is heated and expands. The shaft 12 can now be added. The subsequent cooling produces a rotatably fixed connection between the laminated core and the shaft 12 .
Alternatively, the shaft 12 can also be cooled right down and thus pushed into the laminated core.
A peripheral stop 14 is used here as a stop for the laminated core. After positioning the laminated core with its pressure-cast squirrel cage, the shrink rings 8 are attached to the front faces of the rotor 5 and are likewise connected as described above to the shaft 12 in a rotatably fixed manner for instance. The gaps 9 are then filled by the plastic.
The plastic is provided for instance by way of an assembly apparatus, which prevents the plastic from escaping into the gap 9 at the edges of the shrink ring 8 . The gap 9 can therefore also be filled with plastic at a predeterminable pressure, thereby preventing cavities in the gap 9 . After hardening the plastic, the centrifugal force compensation is ensured as with a precise size compliance of the short-circuit ring 7 and the peripheral surface of the shrink ring 8 .
A further option of introducing plastic into the gap is to apply the plastic to the inner surface of the shrink ring 8 with a predeterminable layer thickness prior to assembly of the shrink ring 8 on the short-circuit ring 7 . By placing and positioning the shrink ring 8 on the short-circuit ring 7 , the extra plastic oozes out of the gap 9 and is removed prior to hardening of the plastic.
The plastic is hardened for instance by applying heat to it in an oven or by means of irradiation. Here either the entire squirrel-cage rotor or only the short-circuit ring 8 provided with the shrink rings 8 and the plastic are exposed to a heat treatment, which can be varied in terms of time and temperature.
FIGS. 3 , 4 shows an embodiment of the shrink ring 8 , which is in principle also shown in FIGS. 1 and 2 . A bowl-type inner surface 15 of the shrink ring 8 surrounds the short-circuit ring 7 on three sides.
In another embodiment of the shrink ring 8 according to FIG. 5 , 6 , a supporting ring 16 surrounds at least part of the radially outer side of the short-circuit ring 7 . The supporting ring 16 is held here by a spoke-type apparatus, which is positioned on the shaft 12 . The gap 9 to be filled with plastic therefore only arises between an outer part of the short-circuit ring 7 and the supporting ring 16 .
While the invention has been illustrated and described in connection with currently preferred embodiments shown and described in detail, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit and scope of the present invention. The embodiments were chosen and described in order to explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. | 4y
|
REFERENCE TO RELATED APPLICATION
The application claims priority to U.S. Provisional Application No. 60/617,969 that was filed on Oct. 12, 2004.
BACKGROUND OF THE INVENTION
This invention generally relates to a tool mounting system for a workpiece transfer system. More particularly, this invention relates to a tool mounting system mountable to a workpiece transfer system.
A workpiece transfer system includes a bar that moves a workpiece between desired locations. Often the workpiece transfer system will move body panels between stamping stations. Tools such as grippers or vacuum cups are attached to the bar and grasp a workpiece at one location and release the workpiece at another location. The tools often utilize pressurized air for actuation and therefore need numerous pneumatic couplings and conduits that are attached to the bar.
In many applications of workpiece transfer systems, the clearance between the bar and the stamping station is limited. Accordingly, each part must fit within certain defined space restrictions. This includes the pneumatic and electrical wires that supply and control actuation of the gripper and vacuum tools.
Further, it is often the case with many transfer systems that multiple workpiece configurations are fabricated within the same line. The stamping dies are changed over along with the tooling required to move the workpieces between stations. Rigidly attached tooling makes change over difficult and time consuming.
Accordingly, it is desirable to design a transfer system that provides for switching of tooling while remaining within the space limitations of the transfer system.
SUMMARY OF THE INVENTION
An example tool mount assembly according to this invention includes drop down connections to aid in mounting of a tool to an adaptor plate and a fail-safe tool mounting system for preventing installation of a tool in an undesired or incorrect manner.
The example tool mount assembly includes an adaptor that is mounted to a bar of a part transfer machine. A plurality of tool mount arms are received within the adaptor and are specifically tailored to provide proper placement of tools such as grippers or vacuum cups relative to a specific panel or part configuration. The adaptor includes several mounting locations to receive a plurality of arms.
Each mounting location of each arm includes a fail-safe mounting allowing only the specified tooling to be installed. In this manner, it is not possible to properly install a tool in an incorrect location. The fail-safe mounting is provided by a specified desired distance between a base quick lock connection and a second connection. Each of the second connections includes a lug that is dropped down into a lug mount. The drop down feature provided by the lug and lug mount ease mounting of the tool to speed tool change over.
These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an example bar tool mounting system according to this invention.
FIG. 2 is another perspective view of the example bar tool mounting system with a rail removed.
FIG. 3 is a schematic view of an example lug mount according to this invention.
FIG. 4 is a top schematic view of example drop down lug mounts according to this invention.
FIG. 5 is a cross-sectional view of the example tool mounting system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , the workpiece transfer system 10 includes a bar 12 that moves a workpiece 20 between workstations (not shown). An adaptor 14 is attached to the bar 12 and supports the tools 18 . The tools 18 extend from removable rails 16 attached to the adaptor 14 . The tools 18 illustrated are pneumatically actuated suction cups. However, other tools as are known would also benefit from the disclosures of this invention, for example mechanical grippers and part present sensing devices.
The rail 16 is part of a rail assembly. There are four rail assemblies 42 , 44 , 46 and 48 illustrated. The tools 18 are mounted to arms 22 that are in turn mounted to the rail 16 of each rail assembly 42 , 44 , 46 and 48 . The position of the tools 18 along the rail 16 is infinitely adjustable such that the configuration and placement of the tools 18 can be tailored to the requirements of a specific application and workpiece 20 .
Each of the rail assemblies 42 , 44 , 46 and 48 include a mount plug 25 that is attachable to selectively releasable mount connector 24 attached to the adaptor 14 . The mount plug 25 is affixed to a first end of the rail 16 for each of the rail assemblies 42 , 44 , 46 and 48 . The mount plug 25 interfaces with the mount connector 24 to communicate pressurized air and provide an electrical connection for any electrical devices mounted to the rail 16 . The mount connector 24 includes a locking device 27 movable between a released position where the rail 16 may be removed and a secured position where the rail 16 is rigidly held into the mount connector 24 , and the desired electrical and pneumatic connections are completed.
The example rail assembly 42 includes a sensor 38 for detecting the presence of the workpiece 20 . The sensor 38 is electrically attached through the interface between the mount plug 25 and the mount connector 24 . The mount connector 24 is in turn in communication with a source of electrical energy and pressurized air. Further, the mount connector 24 is adaptable for providing communication of control signals to the tools 18 mounted to the rail 16 .
The mount connector 24 also provides support of an end of the rail 16 . The second end 28 of the rail 16 is supported by a lug 32 that fits within a lug mount 30 . The lug 32 on the rail 16 is first placed within the lug mount 30 and slid axially into full engagement with the mount connector 24 . The lug mount 30 receives the lug 32 within a slot 35 that includes a vertical portion 37 and horizontal portion 39 . The lug 32 drops within the vertical portion 37 of the slot 35 and is slid axially within the horizontal portion 39 of the slot to facilitate axial engagement and securement of the mount plug 25 within the mount connector 24 . Although a mount connector 24 and mount plug 25 are illustrated, it is within the contemplation of this invention to utilize other mounting devices that are known in the art.
The rail assemblies 42 , 44 , 46 and 48 are installed to the adaptor 14 in a specific location. Each of the rail assemblies 42 , 44 , 46 and 48 are adapted to fit only one location to assure a desired orientation of the rail assemblies 42 , 44 , 46 and 48 to comply with application specific requirements. Each of the rail assemblies 42 , 44 , 46 and 48 are identified by a color code. The color of the lug 32 corresponds to a color on the lug mount 30 to provide a determination of the correct position for mounting of the rail assembly.
The color code in the illustrated example is green for the rail assembly 42 and is indicated schematically by shading 17 B on the the rail assembly 42 and shading 17 A on the lug mount 30 . The rail assembly 46 includes a gold color code schematically indicated at 19 A on the rail 16 and a matching gold color indicated at 19 B on the lug mount 30 . The rail assembly 44 includes a silver color code (not shown) and the rail assembly 46 includes a black color code (not shown). The color-codes 17 A and 19 A disposed on the rail 16 of each rail assembly 42 , 46 comprise a colored tape. The color-codes 17 B and 19 B on the lug mounts 30 are provided by a desired plating color. As appreciated, other colors and method of adhering that color to the lug mount and the rail may be utilized to identify each position on the adaptor 14 with the corresponding one of the rail assemblies 42 , 44 , 46 and 48 . The different color codes provide for easy identification of the proper location for the rail assembly.
Referring to FIG. 2 , the rail assembly 42 is illustrated removed from the rail adaptor 14 . The rail assembly 42 , like the other rail assemblies 44 , 46 and 48 includes a length 50 between the lug 32 and a portion of the mount plug 25 . The length 50 for each of the rail assemblies is unique such that one rail assembly cannot be assembled into the place of another rail assembly. In the example illustrated in FIG. 2 , the rail assembly 46 includes a length 54 that is different than the length 50 such that the rail assembly 46 cannot be assembled in place of the rail assembly 42 . The length 50 between the lug 32 and the end of the mount plug 25 corresponds to a length 52 between the mount connector 24 and the lug mount 30 . The length 52 is measured from a stop of the mount connector 24 and a position within the horizontal portion 39 of the slot 35 within the lug mount 30 .
The length 50 between the lug 32 and the end of the mount plug 25 is a dimension that is fabricated within desired tolerances to provide the desired fit once mounted. As appreciated, some prior art tool mounting devices include multiple critical dimensions that must be closely controlled to provide the desired fit, or event to allow assembly. The instant tool mounting system includes only a single closely held dimension, thereby simplifying assembly, and fabrication.
The rail assembly 42 is easily removable by unlocking the mount plug 25 from the mount connector 24 and moving the entire rail axially away from the mount plug 25 until the lug 32 is free to move vertically within the slot 35 of the lug mount 30 . Another rail assembly including tooling for a differently shaped and configured workpiece can then be installed to provide a relatively quick and easy tooling change over.
In operation, several sets of rail assemblies will be provided that correspond to various and differently configured workpieces. Change over is conducted by removing one set of color-coded rail assemblies and installing another set in the proper color coded locations. Rail assemblies can only be properly installed into corresponding locations due to the different lengths 50 and 54 between the mount connector 24 and the lug mount 30 .
Referring to FIG. 3 , the lug mount 30 is shown without the rail and adaptor for clarity. The lug mount 30 includes the slot 35 having the vertical portion 37 and the horizontal portion 39 . The drop down feature provided by the lug 32 being received in the slot 35 facilitates quick assembly of a rail assembly. The lug 32 includes a bushing 33 that supports the tool and prevents twisting during installation. The drop down feature thereby prevents twisting of the rail assembly during assembly, thereby substantially eliminating the need for an assembler to support the rail assembly during the entire assembly process.
Referring to FIG. 4 , the lug mount 30 is shown schematically that correspond to mounting arrangements for the rail assembly 42 and the rail assembly 46 . The slot 35 includes a width 58 for the lug 32 . The lug 32 includes the bushing 33 supported on a shaft 31 . The shaft 31 includes a diameter 60 that corresponds with the width 58 that provides for assembly of the lug 32 within the slot 35 . The width 58 is tailored to each of the rail assemblies 42 , 44 , 46 and 48 such that each of the rail assemblies 42 , 44 , 46 and 48 includes a tailored width 58 unique to that particular rail assembly.
Accordingly, the rail assembly 46 is partially shown with the lug 32 having a shaft 31 of a diameter 64 different than the diameter 60 for the rail assembly 42 . The lug mount 30 for the rail assembly 46 includes a width 62 of the slot 35 ′ that prevents another rail assembly, such as for example the rail assembly 42 from being installed within the lug mount 30 instead of the rail assembly 46 . Accordingly, the different diameters for each shaft 31 of each of the rail assemblies 42 , 44 , 46 and 48 substantially prevent assembly of a rail assembly in a non-desired orientation.
Referring to FIG. 5 , a cross-section of the transfer system 10 is shown with the adaptor 14 attached to the bar 12 . As appreciated, the transfer system 10 operates within a space-restricted environment. In some applications, it is desired to limit or eliminate mounting of devices or objects to the top of the bar 12 . Such applications may not allow the mounting of electrical wire harnesses and airlines to the top surface of the bar 12 . In such applications, the instant adaptor 14 provides the necessary mounting and communication of air and electric to the tooling without extending substantially beyond the top surface of the bar 12 . The addition of the adaptor 14 adds only the minimal thickness of the adaptor 14 to the overall height of the bar 12 .
Accordingly, the inventive workpiece transfer system 10 includes several features that assure proper configuration of the several rail assemblies 42 , 44 , 46 and 48 that expedite and facilitate quick tool changeover. Different lengths between mounting points for each rail assembly and tailored diameters of shafts for each lug accompanied by color-coded parts provides for fail safe and efficient tool change over. Further, the drop down mounting provided by the lug and lug mount tool mount configuration eases mounting by eliminating awkward and difficult maneuvering of the rail assemblies during the mounting process.
Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention. | 4y
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BACKGROUND OF THE INVENTION
This invention relates to a process for the recovery of hydrogen iodide and more particularly to a process for the recovery of relatively anhydrous hydrogen iodide from a mixture containing hydrogen iodide, water and iodine.
U.S. Pat. No. 4,089,940, issued May 16, 1978 to Norman et al., discloses a process for the thermochemical production of hydrogen which is based upon the employment of the Bunsen reaction: 2H 2 O+SO 2 +I 2 →H 2 SO 4 +2HI. In this process, the Bunsen reaction is carried out using an excess of iodine in order to create a twophase reaction mixture. The lower phase of this mixture, which is then physically separated from the upper phase, contains the major portion of the hydrogen iodide that is produced together with water and iodine. In order to efficiently recover elemental hydrogen from the hydrogen iodide component of this mixture, using a catalytic decomposition reaction or the like, it is felt necessary to first isolate relatively anhydrous hydrogen iodide.
U.S. Pat. No. 4,127,644, which issued on Nov. 28, 1978 to Norman et al., discloses an extractive distillation process for recovering hydrogen iodide from a liquid mixture of H 2 O, I 2 and HI which utilizes phosphoric acid to generate a vapor stream of relatively anhydrous HI. Extractive distillation is an energy-intensive processing step and the subsequent reconcentration of the phosphoric acid is also a fairly energy-intensive step. Less energy-intensive steps or minimization of the use of such energy-intensive steps are desired.
U.S. patent application Ser. No. 921,435, filed July 3, 1978 in the name of Karol J. Mysels, now U.S. Pat. No. 4,176,169, teaches a process for the countercurrent extraction of iodine from a liquid solution containing iodine, hydrogen iodide and water by employing concentrated phosphoric acid. The percentage of iodine in such a liquid solution can be substantially reduced; of course H 3 PO 4 is added to the solution as a result. This countercurrent extraction process can be employed preliminary to an extractive distillation process wherein a relatively anhydrous hydrogen iodide overhead stream is produced. Although such a combination of processes is less energy-intensive than effecting the entire separation through extractive distillation, work has continued in a search for further improvements.
BRIEF STATEMENT OF THE INVENTION
It has been found that, by adjusting the composition of a liquid mixture containing water, hydrogen iodide and iodine and subjecting this mixture to superatmospheric pressure, distinct liquid phases can be caused to appear. One of these phases comprises substantially anhydrous, liquid hydrogen iodide, and the proportional amount of this phase which is formed is determined by the relative proportions of the components in the mixture following the adjustment of the overall composition.
Even if a fourth component, i.e., phosphoric acid, is employed in making the adjustment and, as a result, phosphoric acid is then present as a member of the adjusted composition, distinct liquid phases are still created upon subjection to superatmospheric pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a ternary diagram, based upon mole percent, of the system HI, I 2 and H 2 O;
FIG. 2 is a deployed view of the faces of the regular tetrahedron which depicts quaternary system HI, I 2 , H 2 O and H 3 PO 4 ; and
FIG. 3 is an exploded perspective view of the individual regions of the tetrahedral diagram of the quaternary system, the faces of which are depicted in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention utilizes superatmospheric pressure in order to effect the creation of at least two distinct liquid phases from a mixture containing water, iodine and hydrogen iodide. Although the process disclosed in the aforementioned patent application provides a way for significantly lowering the iodine content of a liquid mixture of this type, the ultimate separation of hydrogen iodide from water is complicated by the fact that simple distillation is ineffective because hydrogen iodide and water form an azeotrope at 57.3 weight percent (w/o) HI and 42.7 w/o water. In the liquid mixture, much of the iodine will be complexed with the hydrogen iodide to form hydrogen polyiodides, e.g., HI 3 , HI 5 , HI 7 , etc.; however, the complexing does not interfere with the creation of separate liquid phases which has now been discovered to occur, and accordingly, the complexing of HI and I 2 is not generally referred to hereinafter. Likewise, although it is convenient to speak of the overall system as a liquid mixture, in fact the various components are soluble in one another, and it would not be inappropriate to term the system a liquid solution.
It has been found that by raising the pressure of a mixture of HI, H 2 O, and I 2 within a certain composition range above an appropriate minimum pressure at an appropriate temperature, it is possible to create two or more immiscible liquid phases, one of which is predominantly HI. This effects a thermodynamically efficient, spontaneous separation of HI from an HI--H 2 O--I 2 mixture.
FIG. 1 is a ternary plot, on a mole percent basis, of the HI--H 2 O--I 2 system which illustrates the main features of the phase behavior of the mixture. The 100 percent water point is shown at the upper peak, with the 100 percent HI point at the lower left-hand corner, and the 100 percent I 2 point at the lower right-hand corner. In geometrical area marked X, two immiscible liquid phases occur, and in the geometrical area marked Y, two immiscible liquid phases are also created, plus the creation of solid I 2 .
FIG. 1 is plotted for values at room temperature, 297 K. (24° C.), and a pressure of about 730kPa (106 psia). In general, as indicated by experimental studies at higher temperatures, a separation process utilizing Region X is not strongly temperature-dependent, and although it is convenient to operate at about room temperature, temperatures as low as 0° C. and as high as 185° C. might be used. On the other hand, experimental studies indicate the depletion of the extent of Region Y upon increasing temperature, so the use of this region appears to be more limited to lower temperatures. There do not presently appear to be any advantages in operating at temperatures lower than room temperature.
Depending upon the temperature characteristics of the incoming stream of the liquid mixture to be treated, it will likely be desirable to operate at an elevated temperature. Depending upon the process steps to which the separated phase will be later subjected, there may not be any advantage in raising the temperature of this stream; however, likely it will be desirable to carry out the separation without substantial cooling so long as the corresponding pressure is considered appropriate. Although the upper temperature limit, i.e., 185° C., lies above the critical temperature of pure HI, i.e., about 150° C., it is expected that certain mixtures will exhibit a pseudocritical temperature greater than that for pure HI, for which separation of liquid phases will still be possible. Thus, the operating temperature will generally be between 0° C. and about 150° C., with operation between about 120° C. and about 150° C. being presently preferred.
Phase separation occurs when the pressure upon the mixture is increased. Although the increased pressure might be provided hydrostatically to the liquid mixture, it is usually provided by compression, and the vapor existing above such a mixture which would be compressed is mainly hydrogen iodide vapor. The amount of superatmospheric pressure which must be exerted upon the mixture at any given temperature is equal to about the vapor pressure of hydrogen iodide at that temperature. If a higher pressure is applied by compression, condensation of HI vapor results. Reference to the vapor pressure of HI in this context should be understood to be directed to the particular system which is being processed. The interaction of components within the liquid system will slightly depress the HI vapor pressure below what it would be for pure HI; however, it should be understood that a higher pressure value than that of pure HI might be required if pressurization is applied hydrostatically in the absence of a vapor phase.
In view of the foregoing, it can be seen that a higher superatmospheric pressure is required when the separation process is carried out at a higher temperature. At about room temperature (25° C.), a pressure of about 113 psia might be used, while at, for example 50° C., a pressure of about 210 psia might be used. At about 70° C., the pressure used would be about 320 psia; whereas at about 95° C., a pressure of about 510 psia would be used. Thus, the approximate vapor pressure of hydrogen iodide at a particular temperature is a consideration in determining the most feasible temperature at which to operate.
Shown in the geometric area designated X in FIG. 1 are a number of tie lines which extend between upper and lower points. These tie lines interconnect the points which represent the respective compositions of HI, I 2 and H 2 O in the two immiscible phases which are spontaneously created by the increase in pressure upon a liquid mixture having a composition lying anywhere along a tie line. The relative amount of each particular phase which is created is determined in inverse proportion to the proximity of the starting composition to the respective end points of the tie line.
For example, if the starting mixture were to have the composition marked by the point AB, which is located about one-quarter of the length of the tie line from the lower end and about three-quarters of the length from the upper end, the volume of the separate liquid phases which are created would be in a 3 to 1 ratio. The lighter phase, which is substantially entirely hydrogen iodide, would be equal to about 75 percent of the total volume, and the heavier phase which has a major portion of water would constitute about 25 percent of the volume. In most instances, the liquid phase containing the anhydrous hydrogen iodide is the lighter of the two phases. However, the density of the phases is reversed at very low iodine levels because the density of the water-bearing phase which contains only a small amount of I 2 is less dense than the anhydrous hydrogen iodide layer.
The two-liquid area in FIG. 1 marked X is of particular interest because one of the two resultant phases is substantially entirely hydrogen iodide. For example, the hydrogen iodide phase will usually contain not more than about 1 weight percent water and, depending upon the starting composition, there may be about 1/10th of a percent of water or less. For room temperature operation, the iodine content of this dehydrated hydrogen iodide phase will usually be in the range of about 1 to 14 weight percent. At higher temperatures the iodine content may increase; however, this phase will still contain a high percentage of hydrogen iodide. In such a two-phase system, the composition of the other phase will vary over a wider span of values, as indicated by the spread of the points at the ends of the tie lines in FIG. 1. In general, the other phase will contain between about 5 and 20 percent water and somewhere between about 40 and 65 percent hydrogen iodide, with the remainder being iodine. Numerical values for the composition of the HI phase and the other phase are available from the tie lines in FIG. 1 in mole percent.
The geometric area in FIG. 1 marked with the designation Y is a three phase region (two liquids and one solid) wherein, upon the appropriate increase in pressure, two liquid phases plus solid iodine (at a temperature below the melting point of iodine) are created. This region is termed "invariant" because the individual compositions of the three phases (including the solid I 2 phase) which are created remain the same regardless of the overall material balance of the starting mixture in this region that is pressurized. The location of the initial overall composition of the mixture within this geometric area determines the relative amount of the three phases; however, in each instance the phase compositions will be the same. Solid iodine will be in equilibrium with both of the liquid phases.
As earlier mentioned, in most instances the liquid HI--I 2 --H 2 O mixture will not be of such a composition that it will fall within either of the geometric areas designated X and Y on the ternary diagram of FIG. 1. Should the product stream fall within either such region, then by simply increasing the hydrogen iodide pressure to the appropriate superatmospheric value, separation could be accomplished. However, normally some adjustment in the composition will be necessary, and it is anticipated that this adjustment procedure may well result in the inclusion of a fourth component into the liquid mixture. In the case where the product stream to be treated has such a large percentage of iodine that it would necessarily lie outside of the geometric regions X and Y, iodine must be removed from the mixture.
It can be seen from FIG. 1 that, in general, the iodine content will be adjusted to less than about 35 mole percent iodine when it is desired to operate efficiently within the two-liquid region, as is presently preferred. Usually the iodine content is reduced to below 20 mole percent, and preferably to below about 10 mole percent, so as to be nearer the lower end of one of the illustrated tie lines. The water content of the product stream will likely also have to be reduced, and from the diagram, it can be seen that that water content must be less than the azeotropic amount, which is indicated in FIG. 1 by a line marked AZ which represents a pseudoazeotrope after the line leaves the left-hand edge of the triangular plot. Generally, the adjustment should be such that the final composition falls below 45 mole percent water, and as earlier indicated, the water content is preferably reduced to less than about 15 mole percent so as to lie near the lower end of one of the tie lines.
Adjustment by reducing the amount of the iodine and/or water components may be effected using any suitable method or additive; however, any additive to the mixture which dissolves therein should be one which does not adversely affect the creation of the two immiscible phases upon subsequent application of superatomospheric pressure. Phosphoric acid is one such agent which is effective in both reducing the iodine content and in shifting the pseudoazeotrope line toward the H 2 O--I 2 axis, thereby allowing other process steps to be effected which will reduce the water content below the initial pseudoazeotropic line. If sufficient H 3 PO 4 is used, the azeotrope can be broken. In accomplishing this objective phosphoric acid dissolves in the aqueous mixture, and so long as it remains in solution, a three-dimensional quaternary plot, as opposed to a ternary plot, becomes necessary to describe the system. Such a plot is depicted in FIG. 3. Testing has shown that the presence of dissolved phosphoric acid does not detract from the inventive concept, namely the spontaneous creation of a dehydrated liquid hydrogen iodide phase upon the application of a certain amount of superatmospheric pressure.
FIG. 2 depicts the four separate faces of the regular tetrahedron quaternary plot with the values shown in mole percent. The exploded perspective view of this regular tetrahedron in FIG. 3 shows each individual three-dimensional region for the HI--I 2 --H 2 O--H 3 PO 4 quaternary system. The center triangle of FIG. 2 represents the face of the tetrahedron where the phosphoric acid level is zero and is the same as the ternary plot shown in FIG. 1. The letters "P" through "U" are used in FIGS. 2 and 3 to label the various corners of the different regions in order to facilitate understanding how the various regions interface with one another.
There are several three-dimensional regions within this quaternary system where it is possible for the separation process to operate. Region A, which appears in the upper center of FIG. 3, is a two-liquid region that is the continuation of the two-liquid region which was referred to as Region X in FIG. 1 wherein one liquid phase is substantially anhydrous HI and the other phase is an aqueous phase. Another face of this three-dimensional Region A appears in the ternary diagram at upper left-hand corner of FIG. 2 which is the ternary diagram for HI--H 2 O--H 3 PO 4 .
As in the case of the ternary plot illustrated in FIG. 1, the quaternary diagram is considered to be relatively temperature insensitive. The pressure considerations mentioned before likewise affect the quaternary system, namely, superatmospheric pressure of about the vapor pressure of hydrogen iodide at that temperature is applied. For example, one mixture falling within the Region A was exposed at room temperature to a pressure of about 110 psia, and two liquid phases were formed. The lower phase was analyzed and was found to contain 95.7 mole percent HI, 3.2 mole percent iodine, 0.48 mole percent H 3 PO 4 and 0.57 mole percent water. On a weight percent basis this is equal to about 93.3 weight percent HI and about 0.08 weight percent water. Other mixtures falling within Region A, when exposed to similar pressure, have resulted in the creation of a bottom phase in which water is not present in a measurable quantity.
Region B, which appears near the left-hand edge of FIG. 3, is a two-liquid-solid region which is a continuation of the same invariant region previously referred to as Area Y in FIG. 1. Although Region B is relatively shallow in its penetration into the tetrahedral volume, its two liquid phases include an almost pure HI phase and it thus remains of potential interest. Three-dimensional Region B does not have the property of invariancy which was true of the geometric Area Y which lies on the face of the tetrahedron.
Region C, which appears below Region A in FIG. 3, is a three-liquid region which lies entirely internal of the tetrahedral volume. Two of the three liquid phases are aqueous phases, with one being relatively high in iodine relatively low in phosphoric acid and with the other being higher in phosphoric acid and lower in iodine. The third liquid phase is almost pure HI and herein lies the potential utility of operation in this region. As an example, one mixture falling within Region C was subjected to about 110 psia at room temperature, and the middle phase of the three phases which formed was tested and found to contain 94.1 mole percent HI and less than 1 mole percent H 2 O.
Region D is a pyramidal region which is entirely internal to the regular tetrahedron and is a 3-liquid-1-solid region that is invariant in its individual phase compositions (as discussed hereinbefore with respect to geometric Area Y). Region D appears generally centrally within FIG. 3, just to the right of Region B, and it extends downward to the I 2 apex. Accordingly, the other three points which define the apices of this pyramid define the compositions of the three immiscible liquid phases that are created. The phase of intermediate density of the 3-liquid phases which are so created as a result of treatment of a composition in this region is of particular interest inasmuch as it is primarily HI with less than about 1 mole percent water.
Region E is another pyramid-shaped region, which is located below Region D in the tetrahedral plot and is a 2-liquid-1-solid region wherein the composition of the resultant immiscible phases varies. The bottom liquid phase has an HI content of more than 90 mole percent and a water content of less than 1 mole percent and is the region of interest. One intended use of this phase, as well as the corresponding phases of the other regions, is to provide an anhydrous hydrogen iodide feed stream for a catalytic cracking process.
Region F is a relatively small, elongated region which also lies entirely internally of the tetrahedron. It is a 2-liquid region but neither liquid phase has a composition which appears to be of particular interest. Region G is wedge-shaped and positioned generally centrally within FIG. 3; it extends to the I 2 apex. Region G is a 2-liquid-1-solid region which also does not appear to have a liquid phase composition of particular interest.
Region H is a large aqueous solution region which extends upward to the H 2 O apex and also downward to the H 3 PO 4 apex but which does not create separate phases upon the application of high pressure. Region I is a liquid-solid I 2 region which, similar to Region H, does not result in the creation of immiscible liquid phases.
In general, room temperature operation in any one of Regions A through E is effective in producing an immiscible liquid phase which comprises at least about 90 mole percent hydrogen iodide, less than 1 mole percent water, less than 1 mole percent H 3 PO 4 and less than 7 mole percent I 2 (which is the saturation level of iodine in hydrogen iodide at about room temperature), and higher temperatures are not considered to adversely affect the creation of immiscible phases. Accordingly, depending upon the composition of the incoming stream which is being provided, a decision is made as to how best to adjust the composition in order to bring it to a desired location within a particularly favorable region. If, for example, phosphoric acid is to be employed in the adjustment steps, standard chemical engineering techniques are employed in order to determine the most favorable overall process from an economic standpoint. These considerations normally include assessments of the equipment that will be required, the overall processing time and prospective energy requirements, as well as the step-by-step yields and the amount of recycling necessary in what would likely be operated as a continuous process. For example, it is preferred to adjust the stream to a composition such that the desired anhydrous HI phase constitutes at least about 50 volume percent of the stream being pressurized; however, other factors may dictate that operation be carried out under conditions where the desired phase constitutes as little as 20 volume percent.
The following Example outlines one embodiment of the separation process wherein one particular characteristic of the ternary phase diagram (FIG. 1) is utilized. It should be understood, however, that this Example is merely illustrative of one such process and in no way defines the limits of the invention concept--there being in addition many different process separation configurations. For example, there are potential configurations wherein mixtures containing H 3 PO 4 could be separated directly (per FIG. 3) without the necessity of distillation of H 3 PO 4 -free, HI, I 2 , H 2 O mixtures, as depicted in the particular Example presented. The choice of separation method is contingent on a number of factors which would be considered in optimizing a system to treat a particular process configuration.
EXAMPLE
Based on one particular application of thermochemical water-splitting, a liquid stream results from the lower acid phase of the Bunsen reaction having a composition of about 39 mole percent I 2 , 12 mole percent HI, and 49 mole percent H 2 O. Its temperature is about 95° C., and its pressure about 30 psia. The above composition is plotted on FIG. 1 as reference point K. Because point K is far from both Regions X and Y (where liquid-liquid separations can be caused to occur) some treatment is required in order to make use of the separation technique.
The liquid stream is first treated in a countercurrent iodine knock-out column where it is caused to flow in countercurrent liquid-liquid contact with a 95 weight percent H 3 PO 4 aqueous stream. The flow rate of the phosphoric acid stream is about 0.75 times the molar flow of the incoming composition being treated, and an exothermic reaction takes place within the column which raises the exit temperature to about 150° C. The stream leaving the bottom of the column, under these conditions, is almost pure I 2 --having a composition of about 98 weight percent I 2 and 2 weight percent H 3 PO 4 . The stream exiting at the top of the knockout column is composed of about 6 mole percent HI, 2 mole percent I 2 , 47 mole percent H 2 O, and 45 mole percent H 3 PO 4 , which falls within the single-liquid region H of FIG. 3. The temperature and pressure of this exit stream are about 150° C. and 30 psia, and the molar flow of this exit stream is about 150 percent of the incoming stream.
The exit stream is supplied to the top end of a countercurrent, multiple-plate, extractive distillation column. About 100 percent H 3 PO 4 is also supplied to the column at a flow rate equivalent to about 0.05 of the molar flow of the infeed stream having composition K. Exiting from the bottom of the distillation column at about 150° C. is about an 85 weight percent aqueous solution of H 3 PO 4 . Exiting from the top is an HI, I 2 , H 2 O gaseous stream, the composition of which is mainly controlled by the design of distillation column, i.e., the amount of H 2 O in this gaseous stream can be adjusted (almost independently of the HI and I 2 composition) by the choice of the number of plates in the distillation column; of course, the temperature also has an overall effect. The aforestated operating conditions create an exiting gas stream having a composition which is 57 mole percent HI, 15 mole percent I 2 , and 28 mole percent H 2 O. This composition is depicted by the point K' on FIG. 1 and lies within Region X. This exiting stream has a mole flow rate about 0.18 times that of the incoming feed stream of composition K.
This gaseous stream is compressed and adjusted in temperature (if desired) to effect separation. Although compression to about 110 psia. at room temperature would be effective, higher temperatures and pressures are desirable in order to obtain a hydrogen iodide liquid stream which is suitable for catalytic decomposition as the next step of an overall scheme to provide H 2 . To this end, the exiting gas stream is lowered to about 120° C., and its pressure is raised to about 750 psia. The resulting liquid mixture spontaneously divides into two immiscible liquids of comparable volume--the upper liquid being the dehydrated HI phase having a composition of about 97 mole percent HI with the remainder being mainly I 2 with less than 0.5% H 2 O and the lower liquid phase having a composition of about 33 mole percent HI, 22 mole percent I 2 , and 45 mole percent H 2 O. The upper phase is separated and can be delivered directly to an HI catalytic decomposition stage, and the lower phase is recycled to the appropriate plate of the multi-stage distillation column. The upper dehydrated HI phase constitutes about 50 volume percent of the compressed mixture; thus, the spontaneous liquid-liquid separation technique provides an essentially water-free composition without having to completely distill the HI, I 2 , H 2 O mixture and while requiring only a small fraction of the amount of 100 percent H 3 PO 4 otherwise needed.
Although the invention has been described with regard to certain preferred embodiments which constitute the best mode presently contemplated by the inventors for carrying out this invention, it should be understood that various changes and modifications which would be obvious to one having the ordinary skill in this art may be made without departing from the scope of the invention which is defined solely by the claims which follow. Various features of the invention are emphasized in the claims appended hereto. | 4y
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This is a continuation-in-part of application Ser. No. 08/631,860, filed on Apr. 12, 1996 now abandoned.
TECHNICAL FIELD
This invention relates generally to an improved extruded open cell mesh. More particularly, this invention relates to an improved open cell mesh which exhibits superior softness while retaining acceptable resiliency, and a method of objectively characterizing the physical parameters of a mesh. Optimization of softness and resiliency is accomplished through control of a variety of physical features of the extruded open cell mesh.
BACKGROUND OF THE INVENTION
The production of extruded open cell mesh is known to the art. Plastic mesh has been used for a variety of purposes, such as mesh bags for fruits and vegetables. Open cell mesh provides a lightweight and strong material for containing relatively heavy objects, while providing the consumer with a relatively unobstructed view of the material contained within the mesh. Such mesh can also be used to make personal cleansing implements.
Prior open cell mesh used to manufacture washing implements has typically been manufactured in tubes through the use of counter-rotating extrusion dies which produce diamond-shaped cells. The extruded tube of mesh is then typically stretched to form hexagonal-shaped cells. The description of a general hexagonal-shaped mesh can be found in U.S. Pat. No. 4,020,208 to Mercer, et al. An example of a counter-rotating die and an extrusion mechanism is described in U.S. Pat. No. 3,957,565 to Livingston, et al. Likewise, square or rectangular webbing has been formed in sheets by two flat reciprocating dies, as shown in U.S. Pat. No. 4,152,479 to Larsen. Although the aforementioned references describe open cell meshes and methods for producing open cell meshes, these references do not describe a soft, resilient product which can be used, for example, as a washing implement. Nor do any of the references listed above define a method of characterizing the softness and resilience of a mesh.
Recently, open cell meshes have been adapted for use as implements for scrubbing, bathing or the like, due to the relative durability and inherent scrubbing characteristics of the mesh. Also, open cell meshes improve lather of soaps in general, and more particularly, the lather of liquid soap is improved significantly when used with an implement made from an open cell mesh. Cleansing ability is generally due to the stiffness of the multiple filaments and nodes of the open cell mesh, causing a friction effect or sensation. To make a scrubbing or bathing implement, the extruded open cell mesh is shaped and bound into one of a variety of final shapes, e.g., a ball, tube, pad or other shape which may be ergonomically friendly to the user of the washing implement. The open cell meshes of the past were acceptable for scrubbing due to the relative stiffness of the fibers and the relatively rough texture of the nodes which bond the fibers together. However, that same stiffness and roughness of prior art mesh was relatively harsh when applied to human skin.
The references described above have been concerned primarily with the strength and durability of the open cell mesh for either containing relatively heavy objects, e.g., fruit and vegetables, or for vigorous scrubbing and cleaning, e.g., of pots and pans. In order to meet the strength and durability requirements, extruded open cell meshes of the past have been manufactured from relatively stiff fibers joined together at nodes whose physical size and shape tended to make them stiff and scratchy, as opposed to soft and conformable.
Hence, heretofore, there has been a continuing need for an improved extruded open cell mesh which would be soft, durable, relatively inexpensive to manufacture, and relatively resilient without being overly stiff and scratchy. More specifically, there was a need for providing an improved open cell mesh, featuring physical characteristics which could be adequately identified and characterized, so that mesh could be reliably made, while exhibiting all of the aforementioned desired physical properties.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved open cell mesh which overcomes the problems described above. It is a further object of the present invention to provide a soft, yet resilient, extruded open cell mesh which is durable enough for use as a scrubbing or bathing implement. It is a related object of the present invention to provide a scrubbing or bathing implement which improves lather when used with soap. It is yet another object of the present invention to provide a method of characterizing an open cell extruded mesh based on its physical parameters and measurable performance tests, so that the improved open cell mesh is easily manufactured and easily recreated as desired.
There is provided herein an extruded open cell mesh comprising a series of extruded filaments which are periodically bonded together to form repeating cells. The bonded areas between filaments are designated as "nodes", while a "cell" is defined by a plurality of filament segments with one node at each of its corners. The extruded cells of preferred embodiments are typically square, rectangular, or diamond shaped, at the time of extrusion, but the extruded mesh is often thereafter stretched to elongate the nodes, filaments, or both, to produce the desired cell geometry and strength characteristics of the resulting mesh. The mesh can be produced through a counter-rotating extrusion die, two reciprocating flat dies, or by other known mesh forming procedures. Tubes of mesh, such as can be produced by counter-rotating extrusion dies, have a preferred node count of between about 70 and about 140, with an especially preferred range of between about 95 and about 115. The node count is measured circumferentially around the mesh tube. A preferred cell count of a tube or sheet of mesh is between about 130 and about 260 cells/meter, with an especially preferred range of between about 170 and about 250 cells/meter. Cell count is measured by a standardized test described herein.
The extruded open cell mesh can be characterized as having an Initial Stretch value, which can be obtained through the use of a standardized test method described herein. A preferred basis weight for mesh of the present invention to be utilized for washing implements is from about 5.60 grams/meter to about 10.50 grams/meter, and an especially preferred basis weight would be from about 6.00 grams/meter to about 8.85 grams/meter. Preferred Initial Stretch values are from about 7.0 inches to about 20.0 inches. More preferred Initial Stretch values are from about 9.0 inches to about 18.0 inches. Most preferred Initial Stretch values are from about 10.0 inches to about 16.0 inches.
In yet another preferred embodiment of the present invention, the extruded open cell mesh is made from low-density polyethylene having a Melt Index of between about 1.0 and about 10.0. The preferred Melt Index for low-density polyethylene is between about 2.0 and about 7.0. Preferred nodes of the present invention have an approximate length, measured from opposing Y-crotches, of from about 0.051 cm to about 0.200 cm. Preferred nodes have a thickness ranging from about 0.020 cm to about 0.038 cm, and a width ranging from about 0.038 cm to about 0.102 cm.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed the same will better be understood from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates an exemplary section of mesh after extrusion;
FIG. 2 illustrates an exemplary extruded section of mesh after stretching;
FIG. 2A illustrates an enlarged exemplary view of a node after stretching;
FIG. 3 is a schematic illustration of testing procedures for measuring an open cell mesh's resistance to an applied weight, which is useful in characterizing the open cell mesh made according to the subject invention;
FIG. 4 illustrates a method of the present invention for counting cells in an open cell mesh;
FIG. 4A illustrates an expanded view of the mesh of FIG. 4;
FIG. 5 illustrates a merged node in open cell mesh;
FIG. 5A illustrates a cross section of the node of FIG. 5;
FIG. 6 illustrates an overlaid node in open cell mesh; and
FIG. 6A illustrates a cross section of the node of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the present preferred embodiments of an improved open cell mesh and preferred methods for characterizing open cell mesh, examples of which are illustrated in the accompanying drawings.
The process of manufacturing diamond cell and hexagonal cell mesh for use in washing implements and the like, involves the selection of an appropriate resin material which can include polyolefins, polyamides, polyesters, and other appropriate materials which produce a durable and functional mesh. Low density polyethylene (LDPE, a polyolefin), poly vinyl ethyl acetate, high density polyethylene, or mixtures thereof, are preferred to produce the mesh described herein, although other resin materials can be substituted provided that the resulting mesh conforms with the physical parameters defined below. Additionally, adjunct materials are commonly added to extruded mesh. Mixtures of pigments, dyes, brighteners, heavy waxes and the like are common additives to extruded mesh and are appropriate for addition to the mesh described herein.
To produce an improved open cell mesh, the selected resin is fed into an extruder by any appropriate means. Extruder and screw feed equipment for production of synthetic webs and open cell meshes are known and available in the industry.
After the resin is introduced into the extruder it is melted so that it flows through extrusion channels and into the counter-rotating die, as will be discussed in greater detail below. Resin melt temperatures will vary depending upon the resin selected. The material's Melt Index is a standard parameter for correlating extrusion die temperatures to the viscosity of the extruded plastic as it flows through the die. Melt Index is defined as the viscosity of a thermoplastic polymer at a specified temperature and pressure; it is a function of the molecular weight. Specifically, Melt Index is the number of grams of such a polymer that can be forced through a 0.0825 inch orifice in 10 minutes at 190 degrees C by a pressure of 2160 grams.
A Melt Index of from about 1.0 to about 10.0 for LDPE is preferred for manufacturing the mesh described herein, and a Melt Index of from about 2.0 to about 7.0 is especially preferred. However, if alternate resin materials are used and/or other ultimate uses for the mesh are desired, the Melt Index might be varied, as appropriate. The temperature range of operation of the extruder can vary significantly between the melt point of the resin and the temperature at which the resin degrades.
The liquified resin can then be extruded through two counter-rotating dies, which are common to the industry. U.S. Pat. No. 3,957,565 to Livingston, et. al., for example, describes a process for extruding a tubular plastic netting using counter-rotating dies, such disclosure hereby incorporated herein by reference. A counter-rotating die has an inner and outer die, and both have channels cut longitudinally around their outer and inner circumferences respectively, such that when resin flows through the channels, fibers are extruded. Individual fibers, e.g., F, as seen in FIG. 1, are extruded from each channel of the inner die as well as each channel of the outer die to form mesh section 10. As the two dies are rotated in opposite directions relative to one another, the channels from the outer die align with the channels of the inner die, at predetermined intervals. The liquefied resin is thereby mixed as two channels align, and the two fibers (e.g., F, as seen in FIG. 1) being extruded are bonded together until the extrusion channels of the outer and inner die are misaligned due to continued rotation. As the inner die and outer die rotate counter-directionally to each other, the process of successive alignment and misalignment of the channels of each die occurs repeatedly. The point at which the channels align and two fibers are bonded together is commonly referred to as a "node" (e.g., N of FIG. 1).
The "die diameter" is measured as the inner diameter of the outer die or the outer diameter of the inner die. These two diameters must be essentially equal to avoid stray resin from leaking between the two dies. The die diameter affects the final diameter of the tube of mesh being produced, although die diameter is only one parameter which controls the final diameter of the mesh tube. Although it is believed that a wide variety of die diameters, for example between about 2 inches and about 6 inches, are suitable for manufacturing the meshes described herein, especially preferred die diameters are in the range of between about 21/2 and about 31/2 inches (about 6.35 and about 8.89 centimeters).
The extrusion channels can likewise be varied among a variety of geometric configurations known to the art. Square, rectangular, D-shaped, quarter-moon, semicircular, keyhole, and triangular channels are all shapes known to the art, and can be adapted to produce the mesh described herein. Quarter-moon channels are preferred for the mesh of the present invention, although other channels also provide acceptable results.
After the tube of mesh is extruded from the counter-rotating dies, it can be characterized as having diamond-shaped cells (FIG. 1) where each of the four corners of the diamond is an individual node N and the four sides of the diamond are four, separately formed filament segments F. The tube is then pulled over a cylindrical mandrel where the longitudinal axis of the mandrel is essentially parallel to the longitudinal axis of the counter-rotating dies, i.e., the machine direction (MD as shown in FIG. 1). The mandrel serves to stretch the web circumferentially resulting in stretching the nodes and expanding the cells. Typically the mandrel is immersed in a vat of water, oil or other quench solution, which is typically 25 degrees C or less, which serves to cool and solidify the extruded mesh.
The mandrel can be a variety of diameters, although it will be chosen to correspond appropriately to the extrusion die diameter. The mandrel is preferably larger in diameter than the die diameter to achieve a desired stretching effect, but the mandrel must also be small enough in diameter to avoid damaging the integrity of the mesh through over-stretching. Mandrels used in conjunction with the preferred 2.5"-3.5" die diameters mentioned above might be between about 3.0" and about 6.0" (about 7.62 cm and about 15.24 cm). Mandrel diameter has an ultimate effect on the Initial Stretch value described in greater detail below.
As the nodes of the diamond cell mesh are stretched, they are transformed from small, ball-like objects (e.g., FIG. 1) to longer, thinner filament-like nodes (e.g., N of FIGS. 2 and 2A). The cells are thereby also transformed from a diamond-like shape to hexagonal-shape wherein the nodes form two sides of the hexagon, and the four individual filament segments F form the other four sides of the hexagon. The geometric configuration of the mesh cells can also vary significantly depending on how the tube of mesh is viewed. Thus, the geometric cell descriptions are not meant to be limiting but are included for illustrative purposes only.
After passing over the mandrel, the tube is then stretched longitudinally over a rotating cylinder whose longitudinal axis is essentially perpendicular to the longitudinal axis of the tube; i.e. the longitudinal axis of the rotating cylinder is perpendicular to the machine direction (MD) of the mesh. The mesh tube is then pulled through a series of additional rotating cylinders whose longitudinal axes are perpendicular to the longitudinal axis, or the machine direction (MD) of the extruded mesh.
Preferably the mesh is taken-up faster than it is produced, which supplies the desired longitudinal, or machine direction, stretching force. Typically a take-up spool is used to accumulate the finished mesh product. As should be apparent, there are a variety of process parameters (e.g., resin feed rate, die diameter, channel design, die rotation speed, and the like) that affect mesh parameters such as node count, basis weight and cell count.
Although the production of open cell mesh in a tube configuration through the use of counter-rotating dies, as described, is preferred for the embodiments of the present invention, alternative processing means are known to the art. For example, U.S. Pat. No. 4,123,491 to Larsen (the disclosure of which is hereby incorporated herein by reference), shows the production of a sheet of open cell mesh wherein the filaments produced are essentially perpendicular to one another, forming essentially rectangular cells. The resulting mesh net is preferably stretched in two directions after production, as was the case with the production of tubular mesh described above.
Yet another alternative for manufacturing extruded open cell mesh is described in U.S. Pat. No. 3,917,889 to Gaffney, et al., the disclosure of which is hereby incorporated herein by reference. The Gaffney, et al. reference describes the production of a tubular extruded mesh, wherein the filaments extruded in the machine direction are essentially perpendicular to filaments or bands of plastic material which are periodically formed transverse to the machine direction. The material extruded transverse to the machine direction can be controlled such that thin filaments or thick bands of material are formed. As was the case with the mesh manufacturing procedures described above, the tubular mesh manufactured according to the Gaffney, et al. reference is preferably stretched both circumferentially and longitudinally after extrusion.
A key parameter when selecting a manufacturing process for the improved mesh described herein is the type of node produced. As was described above, a node is the bonded intersection between filaments. Typical prior art mesh is made with overlaid nodes (FIGS. 6 and 6A). An overlaid node can be characterized in that the filaments which join together to form the node are still distinguishable, although bonded together at the point of interface. In an overlaid node, the filaments at both ends of the node form a Y-crotch, although the filaments are still distinguishable at the interface of the node. Overlaid nodes result in a mesh which has a scratchy feel.
A merged node (FIGS. 5 and 5A) can be characterized by the inability after production of the mesh to easily visually distinguish the filament sections which form the node. Typically, a merged node resembles a wide filament segment. A merged node can have a "ball-like" appearance, similar to that shown by N of FIG. 1, or can be stretched subsequent to formation to have the appearance of node 12 of FIGS. 2 and 2A. In either case, at each end of the node there is a Y-crotch configuration, e.g., 14 of FIGS. 2 and 2A, at the point where the filament segments F branch off the node. For both overlaid and merged nodes, node length 16 of FIG. 2, is defined as the distance from the center of the crotch of one Y-shape to the center of the crotch of the Y-shape at the opposite end of the node. The combination of merged nodes with specific physical characteristics described herein results in a mesh with a consumer preferred range of softness and resiliency, specifically when used in cleansing implements.
As should be apparent, the measurements of node length, node width, and node thickness are to be assessed at the conclusion of the manufacturing process, (i.e., after the material has been through the stretching steps). Preferred nodes of mesh have an approximate length, measured from opposing crotches, of from about 0.051 cm to about 0.200 cm, the nodes have a "thickness" ranging from about 0.020 centimeters to about 0.038 centimeters, and a "width" of from about 0.038 cm to about 0.102 cm.
As will be apparent, the measurement of flexibility of a mesh is a critical characterization of the softness and conformability of a mesh. It has been determined that a standardized test of mesh flexibility can be performed as described herein and as depicted in FIG. 3. The resulting measurement of flexibility is defined herein as Initial Stretch. As schematically illustrated in FIG. 3, the procedure for determining Initial Stretch begins by hanging a mesh tube 20 from a test stand horizontal arm 22, which in turn is supported by a vertical support member 24 and which is in turn attached to a test stand base 26.
As was described above, when the open cell mesh is extruded from a counter-rotating die, the mesh is formed in a tube. If a sheet of mesh is produced, as was described in the Larsen '491 patent, the sheet must be formed into a tube by binding the sheet's edges securely together prior to performing the Initial Stretch measurement. The tube of mesh 20 for testing should be 6.0 inches (15.24 cm) in length, as indicated by length 28. Six inches was chosen, along with a 50.0 gram weight, as an arbitrary standard for making the measurement. As will be apparent, other standard conditions could have been chosen, however, in order to compare Initial Stretch values for different meshes, it is preferred that the standard conditions chosen and described herein are followed uniformly.
As is illustrated in FIG. 3, a standardized weight, is suspended from a weight support member 30, which has a weight support horizontal arm 32 placed through and hung from the mesh tube 20. It is critical that the total combined weight of the support member 30 and the standardized weight together equal 50 grams. Distance 34 illustrates the Initial Stretch, and is the distance which mesh tube 20 stretches immediately after the weight has been suspended from it. A linear scale 36 is preferably used to measure distance 34. For mesh of the present invention it is generally preferred to have an Initial Stretch value of from about 7.0 inches (17.8 cm) to about 20.0 inches (50.8 cm), more preferred to have a Initial Stretch value of from about 9.0 inches (22.9 cm) to about 18.0 inches (45.7 cm), and most preferred to have an Initial Stretch value of from about 10.0 inches (25.4 cm) to about 16.0 inches (40.6 cm).
The resilient property of the open cell mesh can be measured by suspending a larger standardized weight (i.e., 250 grams, as shown in FIG. 3) from the mesh sample 20, and substracting the distance 34 from the distance 35. It is critical that the total combined weight of the support member plus the larger standardized weight equal 250 grams. The result is directly proportional to the resilience level of the mesh.
FIG. 4 illustrates a standardized method for counting cells. The mesh 42 is a section of mesh greater than twelve inches in length. The mesh section 42 is pulled taught along its machine direction, MD. When the mesh is taught, a twelve inch (30.48 cm) segment 44 is marked, for example with a felt tipped marker.
After the mesh section 44 is marked, the mesh section may be stretched transverse to the machine direction to expose the individual cells so that the cells within the mesh segment 44 can be easily counted. A rigid frame 40 may be used to secure a section of mesh 42 so that the segment of mesh being counted 44 is held in place. FIG. 4A illustrates an enlarged portion of the mesh, with numbers 1 through 9 indicating individually counted cells. As can be seen in the enlarged portion, one cell in each row within the marked off section of mesh is counted longitudinally in order to yield the cells per unit length (in FIG. 4 the value would be about 28.5 cells per foot). For the purpose of standardization, a 12.0 inch section of mesh (30.48 cm) is counted to arrive at the number of cells per foot. As will be apparent, counting a shorter or longer segment of mesh is acceptable, the only qualification being that the cell count is ultimately converted to cells/meter.
Characterizing the improved mesh in the direction (T) transverse to the longitudinal axis is accomplished by counting nodes. This method is universal to tubes or flat sheets of mesh and simply comprises selecting a row of nodes and counting them across one row of the sheet or across one circumference of the tube. As should be apparent, the number of nodes in each row of cells will be identical because this is dependent upon extrusion die configuration; every other row of nodes will be shifted half of one cell width (longitudinally). A preferred range for node count for mesh of the subject invention is between about 70 and about 140. An especially preferred range is between about 95 and about 115.
Basis weight is another empirical measurement which can be performed on any tube or sheet of extruded open cell mesh. A length of mesh is measured along the machine direction (MD), then cut transverse to the machine direction, with this measured and cut section then being weighed. The basis weight is preferably tracked in units of grams per meter. For purposes of standardization, a 12.0 inch section of mesh (30.48 cm) is measured, cut and weighed, and the results converted to and reported in grams per meter. The preferred basis weight for mesh of the subject invention is from about 5.60 grams/meter to about 10.50 grams/meter, with an especially preferred range of from about 6.00 grams/meter to about 8.85 grams/meter. The preferred meshes of the present invention can be characterized by a compilation of the aforementioned measurable parameters. As should be apparent, the processing parameters described above can be varied individually or in combination to produce the desired physical properties described herein.
Through the course of experimentation we have discovered that netting materials that are highly flexible under a very low level of stress are perceived by consumers as having a much softer feel on the skin. Further, when this highly flexible netting is formed into a bathing implement, the resulting implement significantly improves consumer ratings for both the cleansing implement as well as the cleaning product it is used with.
We hypothesize that the improved consumer ratings are directly attributable to the more flexible netting materials ability to conform easily to body contours, and to more evenly distribute applied forces thus reducing abrasion. The result is an improved consumer perception of "softness", and not being "scratchy".
Low stress flexibility is quantified by talking a 6 inch sample of netting & measuring the distance it is deformed/stretched under a fixed 50 gram load. This is referred to as a materials Initial Stretch. We have found that for a fixed set of netting parameters (e.g. basis weight & cell size) the greater the magnitude of Initial Stretch the higher the consumer perception of softness.
The benefits of the improved mesh of this invention when used as a washing implement or the like, include improved consumer acceptability and improved softness when the washing implement is rubbed against human skin. Improved lathering is also an important quality of bathing implements made from mesh of the present invention. Lather is improved when the soap is in bar, liquid, and most importantly, gel form. When mesh is used in the production of washing implements, tactile softness, i.e., the feel of the mesh as it contacts human skin is an important criteria. However, resiliency is also an important physical criteria. It is generally intuitive that producing a softer mesh may result in a relatively limp mesh which may not retain the desired shape for the washing implement, i.e., stiffness is sacrificed in favor of softness. However, mesh of the present invention has been found to have the unique properties of being both soft and relatively resilient, i.e. the mesh is able to retain its shape when used as a washing implement. A washing implement which is soft but does not resiliently conform to the skin or object being scrubbed (i.e., the implement is limp), is generally not acceptable to consumers. Therefore, the improved open cell mesh described herein provides a material which is both soft to the touch and, when used to manufacture washing implements, is resilient enough to provide the necessary conformability and resiliency which is preferred by consumers.
Having showed and described the preferred embodiments of the present invention, further adaptation of the improved open cell mesh can be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. A number of alternatives and modifications have been described herein, and others will be apparent to those skilled in the art. For example, broad ranges for the physically measurable parameters have been disclosed for the inventive open cell mesh as preferred embodiments of the present invention, yet within certain limits, the physical parameters of the open cell mesh can be varied to produce other preferred embodiments of improved mesh of the present invention as desired. Accordingly, the scope of the present invention should be considered in terms of the following claims and is understood not be limited to the details of the structures and methods shown and described in the specification and in the drawings. | 4y
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BACKGROUND OF THE INVENTION
Generally the invention relates to the field of solvent bonding. Specifically, the invention relates to the action of the solvent itself to create a bond between at least two parts. In terms of the knowledge and skills involved, it is distinguished from such fields as the field of designing parts which may be bonded together to perform specific purposes, the field of devices to introduce solvent to parts for bonding, and the field of particular chemicals to serve as a solvent.
For many years the technique of joining two parts together through the action of a solvent has been utilized with varying degrees of success. The basic technique simply involves the introduction of a solvent to two surfaces which are then dissolved and which bond together after the solvent evaporates away. Perhaps due to the simplistic basis for the technique of solvent bonding, efforts at refining the technique have generally been based upon an assumption that the resultant bond should obviously be as strong as possible. Importantly, the present invention departs from this assumption and provides a technique through which bonds having a variety of characteristics can be repeatedly created. From the designer's perspective, the invention allows the particular characteristic (or combinations thereof) to be predetermined as appropriate for the particular application. The chosen characteristics are then created automatically through the action of the solvent itself. In so doing, this technique allows the designer the freedom to choose an end result which may have characteristics within a broad range of possibilities. These characteristics include--but of course, are not limited to--the resultant bond's: strength, ability to seal, appearance, failure mode, etc. Significantly, the present invention affords the designer the opportunity to confidently know that the characteristics will be automatically created through the action of the solvent itself rather than through some manipulation or supervision at the assembly level.
Prior to the present invention, those skilled in the art of solvent bonding, seemed to focus their efforts in directions which might be characterized as either: i) efforts designed to control incidental effects of the bonding process, or ii) efforts to externally control the process to create the bond. This is perhaps due to the preconceptions of those involved that, of course, the strongest bond possible was always desired. Representative of the types of improvements directed toward controlling the incidental effects of the bonding process are several patents. In. U.S. Pat. No 4,651,382 to Krolick, a blocking moat design was disclosed to act as a barrier to prevent solvent from penetrating undesirable areas. In applications such as a door hinge, the moat served to avoid the introduction of the solvent to the moveable parts of the hinge itself and thus avoid an undesirable incidental effect of the solvent bonding process. Similarly, U.S. Pat. Nos. 4,256,333, 4,181,549, and 4,137,117 each disclosed designs for a solvent bonded joint which avoided the incidental effect of contamination by the solvent of medically pure fluids. In all of these cases, the inventors designed elements which would act to control some consequential effect of the bonding process. Notably, none of these inventions concern themselves with the characteristics of the resultant bond or--more to the point--with the automatic creation of specific bond characteristics.
The second group of directions those skilled in the art have taken has been the direction of externally controlling the bonding process. Interestingly in many of these types of improvements, the characteristics of the bond itself are not even mentioned. Representative of this direction is U.S. Pat. No. 4,595,446 to Newkirk for an apparatus which automates the application of solvent. Through Newkirk's invention, improvement to devices which create the bond are disclosed. Again, no consideration is given to the characteristics of the resultant bond itself. Rather, through lack of comment, there is a tacit acknowledgement that when it comes to the resultant bond, the solvent itself creates a bond having some characteristics and those characteristics are out of the designer's control.
The presupposition prior to the present invention that the characteristics of the bond itself were not controllable by the designer was most likely due to a bias by those skilled in the art to create the strongest bond in all instances. This is perhaps understood once it is realized that the creation of the solvent bond was generally accomplished as an assembly function. Thus, assemblers created the bond. These persons usually not only possessed a lesser degree of skill than designers but they usually also had little latitude in impacting improvements to the designs. These effects therefore lead to a focus on trial and error efforts or on solvent metering devices rather than unique part designs. This trial and error based level of expertise resulted in a field which may be characterized by slow, incremental improvement rather than dramatic innovation on a wide scale. The technology simply was not viewed as a highly sophisticated technology, rather it was viewed as a rather simple art in which minor improvements are the norm. Surprisingly, the need for and usefulness of bonds having variable characteristics which are automatically created through the action of the solvent has existed for some time. It is also true that the implementing arts and elements have been readily available throughout this time as well. Those skilled in the art simply did not appreciate the aspect of allowing for variable characteristics in the bond because they tended to assume that the strongest bond possible was always desired. This teaching away from the technical direction of the present invention was perhaps bolstered by unrelated arts such as heat bonding materials in which it is also assumed that the strongest bond possible is the most desirable.
SUMMARY OF THE INVENTION
Accordingly it is an object of the present invention to alert those skilled in the art of solvent bonding to the possibility of engineering the resultant characteristics of the bond itself rather than either assuming that the strongest bond is always desirable or merely accepting whatever type of bond that naturally occurs. Keeping with this broadly stated object, it is a goal of the invention to allow the designer a technique to simply assure that the chosen characteristics will be created upon production of the solvent bond. It is also an object to provide an invention which affords the designer the confidence of having such characteristics automatically created through the interaction of his or her design and the solvent rather than through reliance on some skill at the assembly level.
A further object of the present invention is to provide a technique through which changes to the characteristics of a resultant bond can be effected. An important attribute of this technique is that it not only allows for a variety of characteristics, but that it assures that the chosen characteristics be created. In keeping with this desire it is an object of the present invention to minimize or even avoid the consequences of inherent variations in both assembly technique and component manufacture on the characteristics of the resultant bond. It is an aim of the present invention to make the chosen bond characteristics largely independent of such variations. In so doing, the present invention necessitates neither elimination nor inclusion of manufacturing variations; it simply makes them irrelevant.
Another broadly stated object of the present invention is to minimize the need for assembler skill for creation of a proper solvent bond. Particularly it is a goal of the present invention to allow for creation of the chosen characteristics without relying on the particular techniques or steps used to create the bond. In this regard it is an object to make the resultant bond characteristics independent of the technique of introducing solvent to the assembly. It is also a goal to minimize or remove the impact of manufacturing variation on the characteristics of the bond created.
With respect to part design, it is a further object of the present invention to provide a way for the design of the parts themselves to set the characteristics of the bond to be created. In so doing, it is the purpose of the invention to allow the inherent properties of solvents to act so that they automatically create the desired characteristics.
Another broadly stated object of the present invention is to provide a design having basic design parameters from which the designs may be derived to suit the specific criteria involved. Particularly it is a goal to provide an exemplary structure through which a broad range of design parameters may be met by obvious variations.
Naturally, further objects of the invention are disclosed throughout other areas of the specification and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of two parts to be bonded together according to the present invention.
FIG. 2 is an end view of the part to be bonded which has tabs on its surface.
FIG. 3 is a side view in cross section of the two parts as assembled prior to the introduction of solvent.
FIG. 4 is a side view of that configuration depicted in FIG. 3 focusing on only the area to be bonded.
FIG. 5 is a side view in cross section of the two parts after the introduction of solvent and after acting upon the viscous material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although the drawings show a unique structure according to the present invention, the invention is more fundamentally understood through the methods involved rather than the one particular design disclosed. In a fundamental sense, the preferred embodiment the present invention involves the basic step of introducing solvent to create a bond with the unique steps of creating a set or predetermined volume of dissolved material and then acting upon the material while it is dissolved. These two steps each pose unique additions to the prior art techniques. These basic steps significantly depart from the prior efforts by those skilled in the art not only in the steps themselves but in the fact that they expand the realm of design input to include the possibility of engineering specific characteristics of the solvent bond. Significantly these general concepts allow engineering of the solvent bond to occur at the part design stage rather than during the assembly stage.
The aspect of creating a set volume of dissolved or viscous material through a design of the parts has never been accomplished in the fashion of the present invention. According to the invention the designer can determine the appropriate volume of viscous material prior to its creation. This differs significantly from the prior art in which the amount of viscous material was simply happenstance in systems which did not include the need to meter solvent during the assembly phase. In the relevant prior art the amount of viscous material created was dependent upon uncontrolled factors such as the imperfections of the surfaces to be bonded and the technique of the particular assembler. A key difference for the present invention is that the volume of viscous material is predetermined at an amount which is optimally desirable for the particular characteristics desired in the final solvent bond.
The predetermination of the volume of viscous material can be accomplished in a variety of ways. Again, although the structure of the present invention is unique, the general techniques disclosed encompass a much broader scope as they open up a great possibility of designs. Certainly, the more traditional technique of externally metering the solvent introduced to the parts could be utilized. Although this, when combined with the second step of acting upon the parts while they are dissolved, falls within the scope of the present invention, it does not provide the self-optimization aspects of the other techniques disclosed.
To achieve the goal of self-optimization, the technique of creating a reservoir--that is a space between the two parts--which defines a specific volume has been developed. By defining a set volume the reservoir acts to automatically create the appropriate volume of viscous material for the desired characteristics. Certainly a variety of techniques could be used to create the reservoir. Again, one could simply separate the parts manually during assembly. This would, of course, defeat several objects of the present invention, namely, that of self-optimization and that of minimizing assembler actions. The reservoir could also be created through use of internal or external spacers which automatically create the desired reservoir volume. By having a set thickness, the spacers would act to create a set volume. This type of technique not only meets the basic requirements of the present invention but it also accomplishes the goals of self-optimization and minimizing any need for manual techniques at the assembly phase. It also enhances the consistency and reproductibility of specific characteristics by removing variables. If an external spacer is employed, it simply would be removed--without moving the parts relative to each other--prior to filling the reservoir with solvent.
Once the reservoir has been created, solvent is introduced to completely fill the reservoir. The solvent then acts upon the surfaces to create a volume of dissolved or viscous material. At some point the spacer must be removed to allow for the second step of acting upon the viscous material. The removal of the spacer can be accomplished in a variety of ways, including either manual or chemical removal. In a manual instance the spacer would be physically removed from between the parts. Again, although this falls within the scope of the present invention it does not allow achieval of the goal of self-optimization. A more preferable way to remove the spacer is to allow it to be chemically dissolved. This is a particularly desirable technique when the spacer is designed to be a series of tabs or protrusions on one or more of the surfaces. When tabs are used, it would be desirable to provide for their dissolving to be substantially complete at exactly the time when the desired amount of dissolving of the surfaces has occurred. This can be accomplished through proper sizing of the tabs such that each tab's width is less than or equal to twice its height. In this fashion the tab will be substantially dissolved--that is dissolved enough to allow the desired amount of action upon the viscous material--at the proper time thus allowing the surfaces themselves to act to time any action (as discussed below) upon the viscous material. This dissolving would, of course, occur prior to the actual curing of the viscous material.
The second general aspect of the present invention is the concept of acting upon the viscous material prior to its being cured. This differs drastically from the prior art. In the prior art, action upon the viscous material was generally avoided rather than specifically included. By acting upon the viscous material, it is meant that any type of action could be included, the object being simply the accomplishment of one or more of the following goals. First, a goal would be to mix the viscous material. This would assure that the viscous material has a uniform consistency and thus upon curing, that the bond itself would have uniform characteristics throughout. The second goal of acting upon the viscous material would be that of eliminating any pockets of solvent or any areas where the solvent has not been able to dissolve the surface. Since imperfections at even a microscopic level will always remain, this step accommodates the practical aspects of creating solvent bonds. A third goal would be that of substantially purging impurities from the viscous material. Since such parts are rarely manufactured or handled in a clean-room environment, impurities to the surfaces to be dissolved are often introduced. These impurities are a detriment to the creation of the theoretically optimal solvent bond and so should be eliminated to the degree possible. By acting upon the parts while the viscous material exists, these impurities can be substantially purged. It should be understood that total elimination is rarely accomplished. Rather, by the use of the term "substantially purged" it is meant that such impurities be reduced to the largest degree practical.
As mentioned the action upon the viscous material can be accomplished in a variety of ways. These could range from sophisticated techniques such as the use of ultrasound or external conditions to the step of simply displacing one part with respect to the other. Although the former range of possibilities might seem more highly technical and therefore more able to be controlled, they do not achieve the goal of minimizing any input at the assembly level. Rather the step of simply displacing one part with respect to the other accomplishes this very easily with minimal impact upon the assembly phase. This displacement would include a variety of techniques such as simply "squishing" the parts together to only twisting one part with respect to the other. As explained later, by applying a set force manually to compact the parts and thus "squish" the viscous material, several ends are achieved. First, displacement between the two parts occurs. This serves to mix the viscous material to some extent. Second, when the volume of viscous material is reduced, movement of the material perpendicular to the direction of displacement of the parts will occur. This not only enhances mixing the viscous material but it also aids in eliminating any pockets of solvent or non-solvent. Finally, by reducing the volume some of the viscous material is removed. Since the surface itself would contain the greatest degree of impurities and since that surface would be the first to be dissolved, thus it would also be the most fluid material. It would thus tend to be removed first. This would thus aid in elimination of any impurities existing.
In considering the amount of displacement desirable, at least an amount of displacement equal to the largest surface deviation should be included. In this way the bond may be optimized according to the specific parts provided. As mentioned, the displacement can include decreasing the volume of viscous material (i.e. "squishing" it). Interestingly, the process through which a solvent bond is created is such that the decrease in viscous material cannot practically be overdone. Once impurities are substantially reduced, only a minimal amount of solvent is actually necessary to achieve a bond as would be most desirable in a great variety of conditions. This step of decreasing the volume of viscous material not only achieves the three goals mentioned above but it also has the effect of accomplishing other desirable characteristics such as reducing any gaps in the bonded portion, reducing any interstitials that may b contained within the parts themselves, etc.
In addition to the two basic steps of creating a set volume of viscous material and acting upon that material while it is dissolved, the methods may include the additional step of acting upon the viscous material at the optimal time. This time may be determined not simply upon the passage of time but, more accurately, upon the amount of viscous material created or the degree of dissolving having occurred. While certainly this could be empirically tied to the passage of time, the fact that solvent bonds are created in a variety of conditions, temperatures, pressures, and the like, makes the simple elapse of time less effective in optimizing the action upon the viscous material. By basing the action upon the amount of dissolving having occurred, these limitations can be avoided. Significantly the present invention affords the opportunity of automatically determining the optimum amount of dissolving having occurred. This again achieves the desired goal of minimizing the need for input or decisions at the assembly phase and enhances the avoidance of any variations in the resulting bond. It is accomplished by designing the tabs or spacers to substantially dissolve at the appropriate point. Thus by applying a small force to the parts, the force causes a displacement only when the appropriate amount of dissolving of the surfaces has occurred. Again, the extraordinary simplicity of this technique allows it to achieve the desired goals with minimal impact at the assembly phase.
As mentioned earlier, solvent may be introduced to the joint in the traditional fashion. This could involve introducing solvent to at least one of the surfaces and then joining the surfaces together. To simplify the impact of the assembly process, an enhanced technique of introducing the solvent to the area to be bonded is provided. This involves designing the surfaces such that the solvent is distributed through its own natural properties--most notably the property of capillary action. In so doing not only can the solvent be certainly distributed throughout the entire area involved (through the designer's input of course) but even the pattern of distribution can be affected through proper designs. At the assembly phase, this feature can considerably simplify the introduction of solvent. Through proper design the possibility of even dipping the part in solvent exists without over introducing solvent to the area to be bonded. By allowing for the distribution of solvent to occur through the solvents natural properties, the present invention allows the solvent itself to be a controlling factor in assuring the proper characteristics. Thus the characteristics are created independent of the technique used by the assembler of introducing the solvent to the parts. Again, this enhancement serves to achieve the desired goal of self-optimizing the process so that the designer can have a greater degree of certainty that the desired characteristics will in fact be created. The distribution of the solvent thus serves as a way of assuring the creation of the desired characteristic or characteristics.
To accomplish the appropriate distribution of the solvent through capillary action, the designer can design the part such that solvent will only be distributed in certain areas or will be distributed throughout the entire surfaces. In this fashion a solvent bond on a non-porous surface can be greatly impacted by the design of the parts. In so doing the operation of the surfaces act to create the characteristics independent of the variation inherent to any assembly process.
An ancillary benefit to the creation of a reservoir and the use of capillary action is the possibility of increasing the volume of viscous material beyond that typically possible in traditional manual techniques. In some instances the specific solvents involved evaporate so quickly that repeated application of the solvent is required in order to achieve the proper amount of dissolving. As an example, the use of methyl chloride--which boils in ones hand--requires repeated applications in most situations. The present invention accommodates this characteristic by isolating the solvent within a reservoir as previously discussed. Through the use of capillary action and the use of a set reservoir, greater volumes of solvent, and therefore greater volumes of viscous material, can be created without the need for repeated application of the solvent.
In utilizing capillary action, it should be noted that in many design instances it may be desirable to provide for parallel surfaces. In contrast to the prior art in which tapered surfaces were utilized, capillary action will work on parallel surfaces as well. In addition, through using parallel surfaces a more even bond can be created such that equal amounts of solvent per unit surface area will be introduced. In contrast, the prior art which utilized divergent surfaces would cause the majority of bonding to occur at the surfaces' most narrow point.
From the perspective of the scope of the present invention, it should be understood that the methods disclosed herein are shown in their most fundamental forms for the purposes of expanding the great variety of design possibilities. Since each method could be varied and combined in different ways to achieve specific characteristics for a particular application, such variations are intended not only to fall within the scope of the present invention but also to be pursued as each situation may warrant. In keeping with this goal only the most basic design concepts and structure are discussed. Specific applications and modifications can be readily achieved by those skilled in the art once the basic concepts are understood.
As mentioned a basic structure is also disclosed. Referring to FIG. 1, it can be seen that the invention is shown on a representative item, in this case a barbed fitting. The fitting is composed of a male part (1) and a female part (2) which are to be solvent bonded together. Both male part (1) and female part (2) include a cylindrically shaped shoulder (3) which terminates in the bonding surface (4). As can be seen on male part (1), bonding surface (4) has integral to it a series of tabs (5). These tabs (5) extend for a great portion of the width of bonding surface (4). In the vicinity of bonding surface (4) on male part (1), is male sleeve (6). Male sleeve (6) is designed to fit into female sleeve (7) and thus serves to hold the parts in a fixed relationship, to one another in three-dimensional space prior to creation of the solvent bond. Such sleeves should not hold the parts too securely after the bond is created so that any inherent movement necessary during curing is possible.
Referring to FIG. 2 it can be seen that several tabs (5) are included on bonding surface (4) of male part (1). Naturally the tabs could be combined on either male part (I) or female part (2) or could be separately included as discussed earlier. Importantly in this particular embodiment, there are at least three tabs (5). This serves to provide a planer support for the two parts relative to each other such that bonding surfaces (4) can be held in parallel relationship. Naturally a variety of shapes for tabs (5) could be provided. In addition, tabs (5) could actually be a series of bumps or protrusions on one or more of the bonding surfaces (4).
In creating the solvent bond, male part (1) and female part (2) may be fitted together such that male sleeve (6) fits within female sleeve (7) and such that tabs (5) of male part (1) touch bonding surface (4) of female part (2). This creates a set reservoir (8) between male part (1) and female part (2). This reservoir has then introduced to it the solvent to create the solvent bond.
As can be seen through FIGS. 3 and 4, reservoir (8) is defined by bonding surfaces (4) being held a fixed distance apart. This fixed distance (X) is substantially constant across most areas of bonding surfaces (4). Thus, bonding surfaces (4) are parallel to one another.
Once solvent is introduced, capillary action will cause the solvent to wick throughout all areas of bonding surfaces (4). In order to facilitate wicking about the four areas of bonding surfaces (4) defined by the four tabs (5), fluid connection between each area is provided. Referring to FIG. 4 it can be seen that this fluid connection is provided through rounding the inner edge (9) of bonding surface (4) of female part (2). In order to facilitate fluid connection, it is desirable that the opening created by rounding of the inner edge (9) of this female bonding surface be sufficiently large such that the meniscus created by the solvent be able to pull solvent through the opening. This thus serves as a means for distributing the solvent that is integral to the part design.
Referring also to FIG. 4 it can be seen that tab (5) when viewed on end has a width (W) and a height (H). Certainly height (H) will be equal to fixed distance (X) which separates bonding surfaces (4). Importantly, width (W) is no more than twice height (H). This allows the dissolving of tab (5) to occur at the proper time. Naturally width (W) could be substantially less than height (H) in instances where a lesser amount of viscous material is desired. In this fashion tab (5) will substantially dissolve prior to the full amount of dissolving possible. Tab (5) could also have a stepped shape.
Referring to FIGS. 4 and 5, it can be seen that once solvent is introduced to reservoir (8), a volume of viscous material is created. The decrease in this volume is effected by simply displacing male part (1) and female part (2) together as shown by the arrows. This effects a decrease in fixed distance (X) and will decrease the amount of viscous material by forcing some outside the solvent bonded area in the external vicinity of shoulders (3). This affords the advantages discussed earlier. After the displacement, the parts are left to cure such that a solvent bond is created in the area where bonding surfaces (4) existed. Since one integral part is now created, bonding surfaces (4) now cease to exist and are replaced by solvent bonded area (10).
Curing can then be accomplished by simply letting the parts dry--that is allowing the solvent to evaporate from all locations within solvent bonded area (10). To achieve an optimum bond, male part (1) and female part (2) should be free to move with respect to each other and shrink as may naturally occur. Importantly, male sleeve (6) and female sleeve (7) should remain free to move with respect to one another. In addition some small clearance (11) may optimally be included to assure that male part (I) and female part (2) are not held apart undesirably.
Again, this structure represents a relatively simple representative structure to accomplish the methods of the present invention. The foregoing discussion and the claims which follow describe the preferred embodiments only. Particularly with respect to the claims it should be understood that changes may be made without departing from their essence. In this regard it is intended that such changes would still fall within the scope of the present invention. It simply is not practical to describe and claim all possible revisions to the present invention which may be accomplished. To the extent such revisions utilize the essence of the present invention, each would naturally fall within the breath of protection encompassed by this patent. This is particularly true for the present invention since its basic concepts and understandings are fundamental in nature and are intended to open an opportunity for engineers to specifically preengineer solvent bonded joints to accomplish the particular characteristics desirable for their application. | 4y
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BACKGROUND TO THE INVENTION
[0001] THIS invention relates to a padlock.
[0002] A known padlock marketed under the name ENVOSEAL has a lock body of multi-part, moulded plastics construction and a metal hasp which is generally U-shaped. A first leg of the hasp is held captive in the lock body in such a manner that the hasp can pivot and slide relative to the lock body between respective open and closed positions. When the hasp is in a closed position the end of its second leg locates in an opening in the lock body and a transverse hole in the first leg aligns with a transverse hole in the lock body. A frangible plastic seal is clipped to the lock body such that a part of the seal locates in the aligned holes. This prevents pivotal movement of the hasp from the closed to the open position until such time as the seal is broken and removed. Breakage of the seal Indicates that the lock has been tampered with.
[0003] Padlocks of this kind are used in many different applications where a tamper-evident seal is required. One example is in airline trolleys used to store duty free goods, alcoholic beverages and the like. Typically, the padlock in such an application is used to lock the door or drawer of the trolley in a closed position.
[0004] A drawback of the known padlock described above is that it is expensive to manufacture, partly because individually moulded plastic components have to be assembled about the metal hasp and then connected to one another to hold the hasp leg captive. Another drawback is that the design of the padlock dictates that it must have a fairly substantial thickness. For economy of space and packing airline trolleys have a recess to receive the installed lock but this is often too shallow to accommodate the known lock fully. As a result the lock projects from the trolley and can either present an obstruction or itself be impacted on and possibly damaged.
SUMMARY OF THE INVENTION
[0005] According to the invention there is provided a padlock comprising:
a moulded plastics lock body having therein an open-ended passage and an opening spaced from the passage; and a hasp which has first and second spaced apart legs, an end of the first leg being locatable in the passage through a first end thereof and an end of the second leg being locatable simultaneously in the opening, the end of the first leg in the passage being engagable by a breakable seal inserted into the passage through an opposite, second end thereof to lock the hasp relative to the lock body.
[0008] Preferably the lock body is of one-piece, moulded plastics construction nad has a thickness of 8 mm or less. The hasp may be attached to the lock body by a cord or the like. Alterantively it may be attached to the lock body, typically by means of a rivet, in a manner allowing sliding and pivotal movement of the hasp relative to the lock body.
[0009] Other features of the padlock of the invention are set forth in the accompanying description and the appended claims.
[0010] According to another aspect of the invention there is provided a padlock combination comprising the padlock summarised above and a breakable seal having an insertion portion which can be engaged, by movement of the seal through the second end of the passage, with the end of the first leg of the hasp when this end is located in the passage, thereby to lock the hasp relative to the lock body.
[0011] Other features of the padlock combination are also set forth in the accompanying description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings in which:
[0013] FIG. 1 illustrates a padlock and padlock combination according to a first embodiment of the invention in an unlocked condition;
[0014] FIG. 2 illustrates the same padlock and combination in a locked condition;
[0015] FIG. 3 shows a cross-sectional view of the padlock combination of FIG. 1 in the locked condition;
[0016] FIG. 4 shows a cross-section at the line 44 in FIG. 3 ;
[0017] FIG. 5 shows a perspective view of the seal of the padlock combination of FIG. 1 ;
[0018] FIG. 6 shows a cross-section at the line 6 - 6 in FIG. 5 ;
[0019] FIG. 7 shows a perspective view of a padlock combination according to a second embodiment of the invention in a locked condition;
[0020] FIG. 8 shows a cross-sectional view of the second embodiment; and
[0021] FIG. 9 shows, in a cross-sectional view, the movement of the hasp in a cross-sectional view.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] FIG. 1 illustrates a padlock 10 and a padlock combination 12 according to a first embodiment of the present invention. The padlock 10 consists of a lock body 14 and a hasp 16 . The padlock combination 12 consists of the padlock 10 and a seal 20 .
[0023] The lock body 14 is a one-piece plastics moulding. It has a passage 22 extending through it from one open end 23 to an opposite open end 25 . There is a shoulder 24 adjacent the mouth of the passage at the open end 25 , which opens into a generally rectangular recess 27 . The lock body 14 also has a blind opening 26 spaced from and parallel to the passage. Relatively large and relatively small holes 28 and 30 respectively extend tranversely through the lock body
[0024] The hasp 16 is of 2 mm thick flat mild steel and has the shape seen in FIG. 1 . It is generally of U-shape with first and second legs 32 and 34 respectively, the leg 32 being somewhat longer than the leg 32 . The end 34 . 1 of the leg 34 is dimensioned to be a snug slide fit in the blind opening 26 . The end 32 . 1 of the leg 32 is enlarged and is a slide fit in the passage 22 . It includes shoulders 32 . 2 and is formed with a cavity 36 which is undercut by virtue of opposing, re-entrant, inclined tabs 38 . The tabs 38 have inclined outer surfaces 38 . 1 and similarly inclined inner surfaces 38 . 2 .
[0025] The seal 20 , which, together with the padlock 10 , makes up the padlock combination 12 of the invention, is made as a one-piece plastics moulding. It includes a tab portion 20 . 1 from which an insertion portion 20 . 2 projects. The insertion portion has a central stem 20 . 3 and resilient arms 20 . 4 which project rearwardly from the end of the stem.
[0026] In order to close the padlock, the hasp 16 is aligned with the lock body 14 as shown in FIG. 1 . The hasp and lock body are then moved relative to one another so that the legs 32 and 34 enter and slide into the passage 22 and opening 26 respectively. When the hasp is fully inserted the end 34 . 1 of the leg 34 abuts the blind end of the opening 26 , the shoulders 32 . 2 on the hasp abut the mouth of the passage at the open end 23 and the end of the leg 32 abuts the shoulder 24 , as shown in FIG. 2 .
[0027] In order to seal the lock the seal 20 is positioned in the recess 27 and is slid, in direction opposite to that in which the hasp is inserted, into the opposite end 25 of the passage 22 . When the arms 20 . 4 of the insertion portion 20 . 2 encounter the tabs 38 they are inwardly deflected. When the insertion portion is fully inserted the arms move past the tabs and thereafter, with the insertion portion fully located in the cavity 36 , spring back to locate behind the tabs, i.e. the extremities of the legs 20 . 4 of the insertion portion 20 . 2 locate behind the tabs 38 .
[0028] The insertion portion is accordingly clipped into the cavity 36 in the passage 22 , with the tab portion 20 . 1 lying flat in the recess 27 . It will be understood that the seal cannot be withdrawn by a sliding action, because this would merely draw the extremities of the legs 20 . 4 against the inner inclined surfaces 38 . 2 of the tabs 38 . Thus, with the insertion portion 20 . 2 of the seal clipped into the cavity 36 inside the passage 22 , the hasp is effectively locked to the lock body. In order to open the padlock, it is necessary to break the seal 20 .
[0029] This is achieved by bending the tab 20 . 1 in a direction out of the recess 27 , as indicated in FIG. 4 by the arrow 44 , so that the seal breaks at a zone of reduced thickness 20 . 5 between the tab and insertion portions. Once the tab has been broken off, the hasp can be withdrawn from the lock body and the insertion portion can be removed from the cavity 36 .
[0030] Referring to FIGS. 5 and 6 it will be seen that the tab 20 . 1 forms a recessed, upstanding wall 20 . 6 adjacent the root of the stem 20 . 3 . When the insertion portion 20 . 2 of the seal is clipped into the cavity 36 , the wall recess receives portions of the tabs 38 so that the wall lies closely adjacent those tabs. With this feature it is difficult if not impossible to insert a sharp tool past the tab 20 . 1 and into the passage 22 in order to unclip the insertion portion 20 . 2 from the cavity 36 , thereby improving the integrity of the seal.
[0031] In an application of the padlock and padlock combination to, for instance, an airline trolley, the hasp will be arranged in the normal way to pass through openings in the components of the trolley which are to be locked to one another, eg the frame of the trolley and a door or drawer. It will also be understood that in such applications, a visual inspection of the seal to ensure that it is not broken provides an assurance that the trolley has not been opened without authorisation prior to being brought onto the aircraft.
[0032] The large hole 28 provides a suspension point at which the padlock, once unlocked, can be suspended from a hook or the like for re-use at a later stage with a new seal 20 .
[0033] The hasp 16 is formed with a small hole 50 . This hole and the small hole 30 in the lock body provide attachment points for the ends of a thin cord 52 which serves to attach the hasp to the lock body, to prevent inadvertant loss of the hasp.
[0034] FIGS. 7 to 9 illustrate a second embodiment of the invention which does away with the need for a cord 52 to attach the hasp to the lock body. In these Figures, components corresponding to those illustrated in FIGS. 1 to 6 are indicated with the same reference numerals.
[0035] In this embodiment, the hasp 16 is permanently attached, in a manner allowing both sliding and pivotal movement, to the lock body 14 . This is achieved by means of a rivet 60 which passes through the lock body, in the passage 22 , and through an elongate slot 62 in the end 32 . 1 of the leg 32 of the hasp. It will also be noted that the side 64 of the lock body is laterally extended and provides a shoulder 66 adjacent the rivet 60 , and that there is only a single shoulder 32 . 2 .
[0036] FIGS. 7 and 8 show the second embodiment in a closed and locked condition. As in the first embodiment, the legs 32 . 1 and 32 . 2 are located in the passage 22 and blind opening 26 , and the insertion portion 20 . 2 of the seal 20 is clipped into the cavity 36 , inside the passage 22 , with the tab portion 20 . 1 of the seal lying flat in the recess 27 . As before it will be understood that the hasp is effectively locked to the lock body by the seal when the padlock combination is in this locked condition.
[0037] It will also be noted that in the locked position, the rivet 60 is situated at the outer end of the slot 62 .
[0038] In order to open the padlock, the seal 20 is broken by bending the tab portion 20 . 1 in a direction out of the recess. Once the tab portion has been broken away from the insertion portion, the hasp can be slid outwardly as shown in full lines in FIG. 9 . The rivet 60 slides along the slot 62 to its inner end as illustrated. At this stage the insertion portion 20 . 2 of the seal is still retained in the cavity 36 . When the rivet has reached the end of its travel in the slot, the hasp can be pivoted to the broken line position in FIG. 9 , allowing the insertion portion 20 . 2 of the seal to fall out of, or be removed from, the cavity 36 . Abutment of the side of the hasp with the shoulder 66 prevents further pivotal movement of the hasp.
[0039] In order to re-lock the padlock, the opposite procedure is followed, i.e. the hasp is pivoted to the full line position in FIG. 9 and is then slid inwardly to the FIG. 8 position, whereafter a fresh seal 20 can be clipped into place.
[0040] In both embodiments, the inclination of the tabs 38 is a security feature. The tabs and the upstanding wall 20 . 6 of the seal 20 are so designed that the tabs extend into the recess as will be apparent from FIGS. 2 and 7 . The tabs accordingly provide some security against insertion of a sharp tool into the passage 22 with the intention of unclipping the legs 20 . 4 of the seal. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/164,431, filed Jun. 6, 2002, now U.S. Pat. No. 6,852,642, issued Feb. 8, 2005, which is a continuation of application Ser. No. 09/639,550, filed Aug. 16, 2000, now U.S. Pat. No. 6,440,871, issued Aug. 27, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to methods for stripping photoresist from a semiconductor device structure and, in particular, to methods for continuously moving resist stripper across the surface of a semiconductor device structure. More particularly, the present invention relates to resist stripper application methods that include exposing the resist stripper to a gas, to move the resist stripper across the semiconductor device structure, to thin the resist stripper, or to otherwise increase the rate at which the resist stripper removes photoresist from the semiconductor device structure.
2. Background of Related Art
In fabricating semiconductor devices, several material layers, including electrically conductive and insulative layers, are formed and patterned to build various structures upon an active surface of a semiconductor substrate, such as a wafer or other large-scale substrate formed from semiconductive material (e.g., silicon, gallium arsenide, or indium phosphide), thereby forming a semiconductor device structure.
The material layers formed over a semiconductor substrate are typically patterned by forming masks thereover. Photomasks are often employed. The formation of photomasks involves the use of a photoresist material that takes on a specific pattern as the photoresist material is exposed to radiation, such as one or more visible wavelengths of light, through a reticle. In this manner, the reticle and the radiation transmitted therethrough together define the specific pattern of the photoresist. The photoresist is then developed, or cured, so as to maintain the pattern and to form a photomask, which is commonly referred to in the art as a “photoresist” or simply as a “resist.” Once the photomask has been formed, one or more underlying material layers may be patterned through the photomask, such as by way of wet or dry etching processes.
After one or more layers underlying a photomask have been patterned through the photomask to form a semiconductor device structure, the photomask is typically removed. Various processes are known for removing photomasks. Typically, a thin layer of a resist stripper is applied to the semiconductor device structure, such as by spraying the resist stripper onto the semiconductor device structure. Alternatively, a semiconductor device structure bearing a photomask is immersed, or dipped, into a bath of wet chemical resist stripper.
One type of resist stripper that may be used to remove a photomask from a semiconductor device structure is a wet chemical resist stripper, such as an organic resist stripper (e.g., phenol-based and phenol-free organic strippers) or an oxidizing resist stripper (e.g., solutions of sulfuric acid (H 2 SO 4 ) and an oxidant, such as hydrogen peroxide (H 2 O 2 ) or ammonium persulfate). Wet chemical resist strippers typically remove, or dissolve, the photomask with selectivity over (i.e., at a faster rate than) the material of the structures and material layers that underlie and that may be exposed through the photomask or upon removal of the photomask material from the semiconductor device structure. Some such wet chemical resist strippers include one or more types of active chemicals that remove photomasks by reacting with the material or materials of the photomasks. Thus, the concentrations of active chemicals in these wet chemical resist strippers decrease over time, thereby reducing the effectiveness of these resist strippers. Moreover, as the concentrations of reaction products increase in locations where further stripping is desired, the rate at which further reactions between the resist stripper and the photoresist may occur and, thus, the rate at which the photoresist is removed from the semiconductor device structure, are reduced.
As another example, ozonated water may be used as a resist stripper to remove a photomask from a semiconductor substrate. Typically, the water is heated to enhance the ability of the ozone dissolved therein to remove a resist layer from a semiconductor substrate. The heated, ozonated water may be applied to the resist-covered substrate by spraying. As those of skill in the art are aware, ozone effervesces from water relatively quickly. Thus, ozonated water resist strippers lose their effectiveness over time. In addition, as with other types of resist strippers, the rates at which ozonated water resist strippers remove photoresists may be reduced as the concentrations of reaction products increase in the resist stripper.
Conventional processes for applying resist strippers to resist, such as spraying or immersion, do not facilitate continuous movement of the resist strippers across the semiconductor device structure following application and may, therefore, permit the resist strippers to sit, or stagnate, on the resist. Stagnation of resist strippers is somewhat undesirable, however, as the concentrations of reaction products may increase during stagnation and stagnation may, therefore, reduce the rate at which the resist strippers remove photomasks from semiconductor device structures. In addition, when a wet etchant is employed as the resist stripper, the active chemical reactant or reactants of the resist stripper may react with the photomask and, therefore, decrease in concentration. As a result, in a stagnant area, the rate at which such a wet etchant resist stripper removes the photomask and, thus, the ability of such a wet etchant resist stripper to remove the photomask, decreases over time.
In the ozonated water example of a resist stripper, when the resist stripper is at rest, ozone escapes from the water into the atmosphere over time. As the concentration of ozone in the ozonated water resist stripper decreases, the effectiveness of the resist stripper, as well as the rate at which a photomask is removed from a semiconductor substrate therewith, are reduced.
When conventional stripping methods are employed, ozonated water resist strippers typically remove hard-baked photoresist at a rate of about 4,000 Å per minute to less than about 8,000 Å per minute.
The art lacks teaching of methods for introducing one or more gases into or onto a resist stripper to maintain a desired rate for stripping resist from a semiconductor device structure, as well as stripping systems for effecting such methods.
SUMMARY OF THE INVENTION
The present invention includes a method and system for stripping resists from semiconductor substrates while maintaining a desired rate of resist stripping. The method of the present invention includes applying a quantity of resist stripper onto a semiconductor device structure and directing at least one carrier fluid, such as a gas other than ozone, toward the resist stripper or forming at least one gas other than ozone in the resist stripper.
The resist stripper is applied to the semiconductor device structure in a manner that the resist stripper contacts at least a portion of a photomask, or resist, to be removed. For example, the resist stripper may be hot ozonated water that includes a concentration sufficient to remove the resist at a desired rate. Other types of resist strippers, such as wet chemical resist strippers, may also be used in accordance with teachings of the present invention. The resist stripper may be applied to at least a portion of the semiconductor device structure by spraying, in a stream, by dipping the semiconductor device structure in the resist stripper, or otherwise, as known in the art.
The resist stripper may be exposed to one or more gases or other carrier fluids prior to, during, or after application thereof onto a photoresist on the semiconductor device structure. The one or more other, non-ozone gases may thin the layer of resist stripper over the semiconductor device structure or move the resist stripper across a surface of the semiconductor device structure, both of which prevent the formation of or eliminate macroscopic drops of resist stripper on the semiconductor device structure. Alternatively, the one or more gases may be the product of one or more chemical reactions effected by or in the resist stripper, in which case the one or more gases are formed in the resist stripper. In any event, by exposing the resist stripper to one or more gases or other carrier fluids, the rate at which the resist stripper removes photoresist from the semiconductor device structure is increased.
As an example of the manner in which resist stripper may be moved across the surface of the semiconductor device structure, one or more gases under pressure, such as in a jet or stream of liquid or gas, may be directed at least partially across the surface of the semiconductor device structure so as to force resist stripper across the semiconductor device structure. This movement of resist stripper across the surface of the substrate prevents stagnation of the resist stripper and, consequently, prevents a reduction in the rate at which the resist stripper removes the photomask from the semiconductor substrate.
The one or more gases may be directed across the surface of the semiconductor device structure substantially simultaneously with the resist stripper, either by combining the gas or gases with the resist stripper or separately from the resist stripper. Alternatively, the gas or gases may be directed across the semiconductor device structure after the resist stripper has been applied to the semiconductor device structure. When the one or more gases are directed across the surface of the semiconductor device structure, the one or more gases force the resist stripper to move across the device structure.
The one or more gases may be directed across the surface of the semiconductor device structure from a central region thereof toward an outer periphery thereof. Alternatively, the one or more gases may be directed onto a surface of a semiconductor device structure near a peripheral edge thereof so as to move resist stripper across the semiconductor device structure. Application of one or more gases may also be effected in any alternative manner that facilitates the substantially continuous movement of resist stripper across the surface of the semiconductor device structure.
The one or more gases will preferably not react with (e.g., oxidize or otherwise react with or change the nature of) materials of structures or layers of the semiconductor device structure that are exposed through the photoresist or as the photoresist is removed from the semiconductor device structure. Gases that may be used in the method of the present invention include, without limitation, inert gases or gas mixtures, such as nitrogen or noble gases (e.g., argon), air, and gaseous hydrochloric acid.
The present invention also includes systems for applying resist stripper to semiconductor device structures in a manner that effects the inventive method. An example of such a system includes a source of resist stripper, a stripper application component for introducing resist stripper onto a surface of a semiconductor device structure, a gas source, and a gas application component for directing gas at least partially across the surface of the semiconductor device structure so as to move resist stripper across the surface. The stripper application and gas application components may be separate from one another or comprise the same component.
Other features and advantages of the present invention will become apparent to those of skill in the art through consideration of the ensuing description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1A is a schematic representation of a semiconductor device structure including a photomask with resist stripper applied thereto;
FIG. 1B is a schematic representation illustrating another method of applying photoresist to a photomask on a semiconductor device structure;
FIGS. 2A and 2B are schematic representations illustrating movement of resist stripper across the surface of the semiconductor device structure by a gas under pressure;
FIG. 3 is a schematic representation of a variation of the use of a gas under pressure to move resist stripper across a semiconductor device structure when the method of the present invention is used;
FIG. 4 is a schematic representation of the use of gas bubbles in the resist stripper to effect movement of the resist stripper across a semiconductor wafer in accordance with teachings of the present invention;
FIG. 5 is a schematic representation illustrating the alternative, nonhorizontal orientation of a semiconductor device structure as a method according to the present invention is being effected;
FIG. 6 schematically illustrates rotation of a semiconductor device structure as a method according to the present invention is being effected; and
FIGS. 7A and 7B schematically depict systems for effecting methods that incorporate teachings of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1A schematically illustrates a semiconductor device structure 10 , in this case a semiconductor wafer, including a photomask 14 over an active surface 12 thereof. Photomask 14 is formed from polymerized, or consolidated, photoresist and may be either soft-baked or hard-baked, as known in the art. Resist stripper 16 preferably includes ozone (e.g., ozonated water), but may be any other type of resist stripper known and used in the art. Resist stripper 16 may be applied to photomask 14 by known processes, such as by spraying resist stripper 16 onto photomask 14 , as shown in FIG. 1A . As an alternative, resist stripper 16 may be applied to photomask 14 by at least partially immersing photomask 14 in a quantity of resist stripper 16 , as illustrated in FIG. 1B . In any event, resist stripper 16 forms a layer 18 over semiconductor device structure 10 and over any photomask 14 on active surface 12 of semiconductor device structure 10 .
In order to effect the method of the present invention, resist stripper 16 is exposed to one or more gases 20 or other, nongaseous carrier fluids, which effect movement of resist stripper 16 across semiconductor device structure 10 or thin layer 18 of resist stripper 16 , as shown in FIGS. 2A and 2B . Both of these effects of exposing resist stripper 16 to gas 20 facilitate the transfer of reaction products of the reaction between resist stripper 16 and the photoresist of photomask 14 away from the location where such a reaction is occurring. For example, as resist stripper 16 is moved laterally across semiconductor device structure 10 , fresh resist stripper 16 that includes little or no reaction products is continuously supplied to locations where resist stripper 16 reacts with the photoresist of photomask 14 . As another example, by thinning layer 18 of resist stripper 16 , reaction products of the reaction between resist stripper 16 and the photoresist of photomask 14 may more readily escape through layer 18 than if layer 18 were thicker, thus permitting the action between resist stripper 16 and the photoresist of photomask 14 to occur at a faster rate than would be possible if higher concentrations of these reaction products were present at the locations where this reaction is occurring. Other methods of exposing resist stripper 16 to gas 20 in a manner that may increase the rate at which resist stripper 16 removes photoresist of photomask 14 from semiconductor device structure 10 are also within the scope of the present invention.
Turning again to FIGS. 2A and 2B , as an example of a way in which resist stripper 16 may be exposed to one or more gases 20 , a quantity of gas 20 , such as nitrogen, air, or gaseous hydrochloric acid, or another, nongaseous carrier fluid, is directed under pressure (either positive ( FIG. 2A ) or negative ( FIG. 2B )) at least partially across layer 18 . Gas 20 does not include ozone. By directing gas 20 at least partially across layer 18 , resist stripper 16 of layer 18 is moved across semiconductor device structure 10 in a plane substantially parallel to the plane of semiconductor device structure 10 , such as in the directions of arrows 22 . In this manner, products of the chemical reaction between the ozone of resist stripper 16 and the material or materials of photomask 14 are continuously moved away from photomask 14 , thereby facilitating subsequent reactions between the ozone of resist stripper 16 and the photoresist of photomask 14 , as well as the removal of photoresist from semiconductor device structure 10 , to proceed at a faster rate. In addition, by directing one or more gases 20 at least partially across layer 18 , the thickness of layer 18 may be reduced, which permits reactants of the reaction between the ozone of resist stripper 16 and the photoresist of photomask 14 to more readily pass through layer 18 and disperse.
As shown in FIGS. 2A and 3 , gas 20 may be directed toward layer 18 in a pressurized jet 30 . Pressurized jet 30 may be directed toward layer 18 from substantially the same location as that from which resist stripper 16 is introduced over semiconductor device structure 10 , as shown in FIG. 3 , or from a different location than that from which resist stripper 16 is directed over semiconductor device structure 10 , as depicted in FIG. 2A .
With reference to FIG. 4 , gas 20 may alternatively be directed across layer 18 of resist stripper 16 in the form of bubbles 32 on the surface of or residing within layer 18 . The movement of bubbles 32 across layer 18 may effect the substantially continuous movement of resist stripper 16 over semiconductor device structure 10 . As bubbles 32 move through layer 18 , products of the reaction between resist stripper 16 and the photoresist of photomask 14 may be carried by bubbles 32 away from the locations in which photoresist removal reactions are occurring. In addition, bubbles 32 may move layer 18 across semiconductor device structure 10 as bubbles 32 flow therethrough. Both of these effects of bubbles 32 facilitate the passage of products of the reaction between resist stripper 16 and the photoresist of photomask 14 away from the locations in which this reaction is occurring, thereby increasing the overall reaction rate.
FIG. 5 depicts the nonhorizontal orientation of a semiconductor device structure 10 . When semiconductor device structure 10 is nonhorizontally oriented, gravity further facilitates thinning of layer 18 and movement of resist stripper 16 in layer 18 over semiconductor device structure 10 .
Preferably, semiconductor device structure 10 remains substantially stationary as the method of the present invention is being effected. Thus, existing automated wet bench equipment may be used to conduct the method of the present invention.
As another alternative, which is illustrated in FIG. 6 , a semiconductor device structure 10 may be rotated in a plane thereof to further effect thinning of layer 18 and movement of resist stripper 16 in layer 18 over semiconductor device structure 10 by centrifugal force. Again, the additional thinning and movement of layer 18 provided by such rotation further accelerate the rate at which resist stripper 16 removes the material or materials of photomask 14 from semiconductor device structure 10 .
Gas 20 ( FIG. 3 ) to which layer 18 is exposed may itself increase the rate with which resist stripper 16 removes the material or materials of photomask 14 from semiconductor device structure 10 or otherwise enhances the removal of photomask 14 by resist stripper 16 . Chemicals or chemical mixtures that form gas bubbles in layer 18 ( FIG. 4 ) may also increase the rate at which the resist stripper 16 of layer 18 removes the photoresist of photomask 14 by action of the bubbles, as discussed previously herein with reference to FIG. 4 , or by causing the formation of gaseous products as resist stripper 16 reacts with the photoresist, which products form and are carried away in bubbles. For example, hydrochloric acid decreases the pH of resist stripper 16 and increases the concentration of ozone in resist stripper 16 , while decreasing the concentration in resist stripper 16 of carbonic acid (H 2 CO 3 ), which is a product of the reaction between an ozonated resist stripper 16 and a photoresist. In addition, by adding hydrochloric acid to resist stripper 16 , the concentration of hydrogen ions in resist stripper 16 increases, which forces the carbonic acid in resist stripper 16 to be broken up into carbon dioxide (CO 2 ) gas and water (H 2 O) rather than into carbonate ions (CO 3 − ) and hydrogen ions (H + ). As a result, more carbon dioxide, which is a gas, is formed. Carbon dioxide readily diffuses, effervesces, or bubbles out of resist stripper 16 , away from the reaction between resist stripper 16 and the photoresist of photomask 14 , and will, therefore, not increase in concentration in the presence of the reaction or decrease the rate at which this reaction occurs. Correspondingly, the formation of carbonic acid, which is an ion that tends to remain dissolved in resist stripper 16 , is reduced. Thus, carbonic acid concentrations will not increase as rapidly as if the hydrogen ions from hydrochloric acid were not present and, as a result, the rate at which resist stripper 16 reacts with the photoresist of photomask 14 is not significantly decreased. As directing hydrochloric acid toward layer 18 of resist stripper 16 increases the formation of carbon dioxide gas in resist stripper 16 , the direction of one or more gases 20 toward layer 18 may be effected by introducing either gaseous or liquid hydrochloric acid into layer 18 . In addition, when hydrochloric acid is used, the rate at which resist stripper 16 removes the material or materials of photomask 14 may be increased without actually moving layer 18 or thinning layer 18 .
FIG. 7A illustrates an exemplary resist stripping system 40 for effecting the stripping method of the present invention. Resist stripping system 40 includes a wafer support 42 , upon which a semiconductor device structure 10 having photoresist thereon is positioned. Wafer support 42 may be configured to orient a semiconductor device structure 10 positioned thereon nonhorizontally. Wafer support 42 may also be configured to rotate a semiconductor device structure 10 positioned thereon. A stripper applicator 44 of resist stripping system 40 obtains resist stripper 16 from a source 46 and applies resist stripper 16 to a photomask 14 on a semiconductor device structure 10 disposed on wafer support 42 . Resist stripping system 40 also includes a gas source 48 , from which gas 20 is supplied and which communicates with a gas output element 50 that directs gas 20 toward wafer support 42 so as to effect the direction of gas 20 at least partially toward resist stripper 16 or to otherwise expose resist stripper 16 to gas 20 .
Alternatively, as shown in FIG. 7B , a resist stripping system 40 ′ incorporating teachings of the present invention may include a chemical output element 54 to which directs a chemical 56 , such as hydrochloric acid, from a chemical source 52 toward wafer support 42 so as to expose resist stripper 16 on a semiconductor device structure 10 positioned on wafer support 42 to chemical 56 and to induce the formation of gas bubbles 32 ( FIG. 4 ) in resist stripper 16 .
When methods incorporating teachings of the present invention are employed, the rates with which these ozonated resist strippers 16 remove hard-baked photoresists are at least about 8,000 angstroms per minute up to about 12,000 angstroms per minute and greater, as compared with conventional resist stripping methods employing ozonated resist strippers, which remove hard-baked photoresists at much slower rates. While the methods of the present invention are particularly useful for increasing the rates with which ozonated resist strippers 16 remove photoresists, the teachings of the present invention may also be employed to increase the rates with which other types of resist strippers 16 remove photoresists.
Although the foregoing description contains many specifics, these should not be construed as limiting the scope of the present invention, but merely as providing illustrations of some of the presently preferred embodiments. Similarly, other embodiments of the invention may be devised which do not depart from the spirit or scope of the present invention. Features from different embodiments may be employed in combination. The scope of the invention is, therefore, indicated and limited only by the appended claims and their legal equivalents, rather than by the foregoing description. All additions, deletions and modifications to the invention as disclosed herein which fall within the meaning and scope of the claims are to be embraced thereby. | 4y
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TECHNICAL FIELD
[0001] The present invention relates to a ceramic heater for heating a semiconductor wafer that is an object to be heated, used for a CVD device, a sputtering device in a manufacturing step for a semiconductor device, or an etching device for etching a generated thin film, or the like, and relates also to a method of manufacturing the same.
BACKGROUND ART
[0002] For a heater used for heating a semiconductor wafer in a manufacturing step for a semiconductor device, there have been used a ceramic heater in which on oxide ceramics, nitride ceramics, or a heat resistant substrate covered with an insulating layer such as an oxide film and a nitride film, there is formed a heating element pattern composed of metals such as nickel, chrome, tantalum, molybdenum, tungsten, and platinum or a conductive ceramic thin film such as silicon carbide and pyrolytic graphite.
[0003] To form the heating element pattern, there have been: a method for forming a resistant heating element by a coating method using a method such as a screen print; a method for forming a resistant heating element using a physical vapor deposition such as sputtering or a plating method; or a method for forming a resistant heating element using a chemical vapor deposition.
[0004] In the method for forming a resistant heating element by the coating method, a method such as a screen print is used to form the heating-element pattern on the surface of a substrate. However, the print thickness becomes irregular, so does a resistance value of the formed resistant heating element. This may result in a problem that the symmetry of a heater temperature distribution becomes poor.
[0005] In the method for forming a resistant heating element by using a physical vapor deposition such as sputtering, a plating method, or a chemical vapor deposition, these methods are firstly used to form a metal layer or a conductive ceramic layer having smaller thickness irregularity on the surface of the substrate. Thereafter, by performing etching processing or sand blast processing or performing laser machining (for example, see JP-A-2006-54125), the heating element is trimmed so as to form a heating-element pattern having a better temperature distribution symmetry. However, when the heating element is thus trimmed, the thickness or the width of the heating pattern is reduced, and this results in a resistance value being larger than the target resistance value.
[0006] Upon actually using the heater, a normal-rated voltage or a normal-rated current is determined for a power supply or wiring. Thus, unless the resistance value is contained within a certain range (when there is a large variation from the target resistance value), it is not possible to input sufficient power required for heating by a previously prepared power supply device, and as a result, it may not be possible to heat up to a predetermined target temperature.
[0007] Therefore, the heating pattern is firstly produced so that the resistance value is smaller than the target resistance value, and thereafter, the heating pattern is trimmed thereby to perform an adjustment in the temperature distribution by the irregularity of the resistance value or an adjustment for matching to the target resistance value (see Japanese Patent No. 3952875).
[0008] When the heating element is trimmed by the sand blast processing, the etching processing, and the laser machining, the adjustment for the irregularity of the resistance value or the adjustment for increasing the resistance value may be possible. However, in contrary thereto, it is difficult to make an adjustment for decreasing the resistance value. Therefore, it is necessary to previously lower the resistance value of the heating element pattern so that the target resistance value is obtained.
SUMMARY OF INVENTION
Technical Problem
[0009] In view of the problems inherent in the above-described conventional technology, an object of the present invention is to provide a ceramic heater that eliminates the necessity of manufacturing with a low resistance value in advance and is capable of adjusting to a lower value, and also to provide a method of manufacturing the same.
Solution to Problem
[0010] A ceramic heater of the present invention is a ceramic heater comprising: a ceramic substrate and a conductive heating element arranged inside of or on a surface of the ceramic substrate, wherein said conductive heating element is made of a material which had undergone a high-temperature heat treatment. It is preferable as follows: a temperature of the high-temperature heat treatment is in a range of 1000 to 2200° C.; the resistance value of the conductive heating element is 0.1 to 20% lower than that of the same conductive heating element before the heat treatment; the conductive heating element is any one of pyrolytic graphite, boron-containing pyrolytic graphite, and silicon-containing pyrolytic graphite; and the ceramic substrate is oxide ceramics, nitride ceramics, or a heat resistant substrate covered with an insulating layer such as an oxide film or a nitride film.
[0011] Also, a method of manufacturing a ceramic heater of the present invention is a method of manufacturing a ceramic heater which comprises a ceramic substrate and a conductive heating element arranged inside of or on a surface of the ceramic substrate, the method comprising a step of adjusting a resistance value of the conductive heating element by performing high-temperature heat treatment. It is preferable that the high-temperature heat treatment of the conductive heating element is performed continuously or simultaneously with a formation processing step of an insulating protective layer.
ADVANTAGEOUS EFFECTS OF INVENTION
[0012] According to the present invention, in a ceramic heater in which a conductive heating element is arranged inside of or on a surface of a ceramic substrate, when a high-temperature heat treatment is performed in a range of 1000 to 2200° C., a resistance value can be downwardly adjusted by 0.1 to 20%. Thus, upon arranging a conductive heating element, it is not necessarily needed to make the resistance value small in advance, an excessive use of a material of the conductive heating element is not needed any more, a cost for forming the conductive heating element can be also lowered.
[0013] Further, the high-temperature heat treatment step can be performed continuously or simultaneously with a formation of an insulating ceramic protective layer, and thus, a heater of a desired resistance value can be easily obtained without increasing unnecessary steps.
BRIEF DESCRIPTION OF THE DRAWING
[0014] FIG. 1 is an explanatory schematic diagram showing a ceramic heater according to the present invention.
DESCRIPTION OF EMBODIMENTS
[0015] As a result of extensive studies, the present inventor, et al., have found that when high-temperature heat treatment is performed on a conductive heating element, various characteristics such as the crystallinity of the conductive heating element, the orientation, the crystallite size, and the density are changed, and thereby, a resistance value is changed.
[0016] Therefore, the present inventor, et al., carried out high-temperature heat treatments on the conductive heating element in advance under a plurality of conditions, measured the change in resistance value, and based thereon, formed a conductive heating element (pattern). After confirming the resistance value, the present inventor, et al., set heat treatment conditions to carry out the heat treatment, and as a result, confirmed that it would be possible to obtain a desired resistance value.
[0017] Further, the present inventor, et al., confirmed that these heat treatments could be processed continuously or processed simultaneously with a formation processing step of an insulating protective film performed to secure the insulation on the conductive heating element.
[0018] Hereinafter, a ceramic heater and a method of manufacturing the same, of the present invention, will be described in detail.
[0019] According to the present invention, a high-temperature heat treatment is performed on a ceramic heater provided with a conductive heating element inside of or on the surface of a ceramic substrate. Thereby, various characteristics such as the crystallinity of the conductive heating element, the orientation, the crystallite size, and the density are changed, whereby a resistance value of the conductive heating element is adjusted.
[0020] The reason why the resistance value is changed is probably due to the following facts: in a conductive heating element produced (formed) by a screen print method, a sputtering method, a plating method, and a CVD method, when the heat treatment is performed, the “crystallinity is changed from non-crystalline to crystalline, and thus, the resistance is decreased”, the “crystalline orientation is changed, and thus, the anisotropy is increased. As a result, electrons become easy to flow in that direction, thereby decreasing the resistance”, “as a result of sintering being occurring among particles, the crystalline size becomes large, and thus, the resistance at a particle interface is decreased”, etc.
[0021] In particular, in a pyrolytic-graphite heating element produced by a CVD method, when a temperature history at the time of the film formation is changed, the crystalline orientation differs greatly, and thus, the electric ratio resistance also differs.
[0022] Thus, also when the heat treatment is performed after the production (formation), the orientation is changed, thereby increasing the anisotropy. As a result, it is highly probable that the resistance is decreased. It is very highly probable that the above-described resistance change can sufficiently occur not only in the pyrolytic graphite but also in other metallic materials.
[0023] The heat treatment can be performed simultaneously with the formation of an insulating ceramic protective layer when the resistance value of the produced (formed) conductive heating element can be predicted through experience, etc., and thus, the adjustment for decreasing the resistance can be performed without increasing unnecessary steps.
[0024] The temperature of the high-temperature heat treatment is in a range of 1000 to 2200° C. A material of the conductive heating element listed in the present invention will change little in a temperature range lower than this lower limit temperature.
[0025] In a temperature range higher than that, between the ceramic substrate and the conductive heating element, and the conductive heating element and the insulating ceramic protective layer, the both components are peeled off due to the heat stress occurring therebetween resulting from a difference in thermal expansion. Therefore, the temperature preferably is in a range of 1000 to 2200° C.
[0026] Further, in consideration of reducing a heat stress load at a high temperature or forming the insulating ceramic protective layer, the temperature range more preferably is of 1500 to 2000° C.
[0027] The resistance change rate in the temperature range of 1000 to 2200° C. is about 0.1 to 20%.
[0028] When the conductive heating element is pyrolytic graphite, boron-containing pyrolytic graphite, and silicon-containing pyrolytic graphite, it becomes possible to withstand the high-temperature heat treatment, and due to the heat treatment, various characteristics such as the crystallinity, the orientation, the crystallite size, and the density are changed, and thus, the resistance value is changed. Therefore, this is preferable.
[0029] With respect to the ceramic substrate, it is preferable to select oxide ceramics such as quartz and alumina, nitride ceramics such as nitride aluminum and nitride silicon, or a conductive heat-resistant substrate covered with an insulating layer such as an oxide film or a nitride film (for example, a substrate containing C or a metallic element), etc., because these can withstand a high-temperature heat treatment for a resistance adjustment, and also, preferable to select that which has a small difference in thermal expansion from the conductive heating element.
EXAMPLES
[0030] In the following preliminary experiments and examples, the ceramic heater shown in FIG. 1 was produced. In FIG. 1 , reference numeral 1 denotes a ceramic substrate, 2 denotes a conductive heating element, and 3 denotes an insulating ceramic protective layer.
First Preliminary Experiment
[0031] On a pyrolytic boron nitride substrate of 2 mm in thickness, methane gas was thermally decomposed under a vacuum condition of 1500° C. and 50 Torr to form a pyrolytic graphite layer of 100 μm in thickness. A heating pattern was machined on the resultant layer.
[0032] When the resistance value of the heating pattern composed of the pyrolytic graphite was measured by a four-proved method, the value was 8.56Ω. Subsequently, high-temperature heat treatment was performed for two hours under a vacuum condition of 50 Torr at each temperature shown in Table 1 between 900 and 2300° C. Thereafter, ammonia, boron trichloride, and methane gas were reacted under a vacuum condition of 1800° C. and 100 Torr to form carbon-containing pyrolytic boron nitride insulating layer of 100 μm in thickness, whereby the ceramic heater was produced.
[0033] Thereafter, the resistance value of the heating pattern was measured again by the four-proved method, the resistance value at each heat-treatment temperature was 8.56 to 6.74Ω. Measurement results of changes of these resistance values are listed in Table 1.
[0034] When the heat-treatment temperature was equal to or less than 900° C., there was little change in resistance value.
[0035] Further, it was confirmed that at equal to or more than 2300° C., one portion of the pattern was peeled off.
[0000]
TABLE 1
Resistance Value Change Rates in [First Preliminary
Experiment]
Resistance
Heat
value after
treatment
Resistance
heat
temperature
value during
treatment
Change
(° C.)
formation (Ω)
(Ω)
rate (%)
Notes
Ex. 1
900
8.56
8.56
0.0
Ex. 2
1000
Same as
8.53
0.4
above
Ex. 3
1200
Same as
8.40
1.9
above
Ex. 4
1500
Same as
8.09
5.5
above
Ex. 5
1800
Same as
7.61
11.1
above
Ex. 6
2000
Same as
7.17
16.2
above
Ex. 7
2200
Same as
6.90
19.4
above
Ex. 8
2300
Same as
6.74
21.3
Pattern
above
peeled
First Example
[0036] Using the first preliminary experiment as a reference, the ceramic heater was produced.
[0037] Similar to the first preliminary experiment, a pyrolytic graphite layer was formed on a pyrolytic boron nitride substrate of 2 mm in thickness, and the heating pattern was machined on the resultant layer.
[0038] When the resistance value of the heating pattern composed of the pyrolytic graphite was measured by a four-proved method, the value was 8.03Ω. A target resistance value was set to 7.10Ω (target resistance change rate was set to 11.6%), and the subsequent high-temperature heat treatment was performed at 1800° C.
[0039] At the temperature of 1800° C., the high-temperature heat treatment was performed for two hours under a vacuum condition of 50 Torr, and thereafter, ammonia, boron trichloride, and methane gas were reacted under a vacuum condition of 1800° C. and 100 Torr to form a carbon-containing pyrolytic boron nitride insulating layer of 100 μm in thickness, whereby the ceramic heater was produced.
[0040] Subsequently, the resistance value of the heating pattern was measured again by the four-proved method, the value was 7.15Ω (resistance change rate was 11.0%). Thus, it was possible to obtain a resistance value close to the target value of 7.10Ω.
Second Preliminary Experiment
[0041] On a pyrolytic boron nitride substrate of 2 mm in thickness, boron trichloride and methane gas were thermally decomposed under a vacuum condition of 1500° C. and 50 Torr to form a boron-containing pyrolytic graphite layer of 100 μm in thickness. A resistance value of a heating pattern composed of the boron-containing pyrolytic graphite was measured by a four-proved method, and the value was 7.89Ω.
[0042] Subsequently, similar to the first preliminary experiment, the ceramic heater was produced, and the resistance value changed by the heat treatment at each temperature shown in Table 2 was 7.89 to 6.14Ω.
[0043] The results of the resistance value change are listed in Table 2.
[0044] When the heat-treatment temperature was equal to or less than 900° C., there was little change in resistance value. Further, it was confirmed that at equal to or more than 2300° C., one portion of the pattern was peeled off.
[0000]
TABLE 2
Resistance Value Change Rates in [Second Preliminary
Experiment]
Resistance
Heat
value after
treatment
Resistance
heat
temperature
value during
treatment
Change
(° C.)
formation (Ω)
(Ω)
rate (%)
Notes
Ex. 11
900
7.89
7.89
0.0
Ex. 12
1000
Same as
7.87
0.3
above
Ex. 13
1200
Same as
7.77
1.5
above
Ex. 14
1500
Same as
7.36
6.7
above
Ex. 15
1800
Same as
7.02
11.0
above
Ex. 16
2000
Same as
6.63
16.0
above
Ex. 17
2200
Same as
6.33
19.8
above
Ex. 18
2300
Same as
6.14
22.2
Pattern
above
peeled
Second Example
[0045] Using the second preliminary experiment as a reference, the ceramic heater was produced.
[0046] Similar to the second preliminary experiment, a boron-containing pyrolytic graphite layer of 100 μm in thickness was formed on a pyrolytic boron nitride substrate of 2 mm in thickness, and the heating pattern was machined on the resultant layer. A resistance value of the heating pattern composed of the boron-containing pyrolytic graphite was measured by a four-proved method, and the value was 7.12Ω.
[0047] A target resistance value was set to 6.65Ω (target resistance change rate was set to 6.6%), and the subsequent high-temperature heat treatment was performed at 1500° C. At the temperature of 1500° C., the high-temperature heat treatment was performed for two hours under a vacuum condition of 50 Torr, and thereafter, ammonia, boron trichloride, and methane gas were reacted under a vacuum condition of 1800° C. and 100 Torr to form a carbon-containing pyrolytic boron nitride insulating layer of 100 μm in thickness, whereby the ceramic heater was produced.
[0048] Subsequently, the resistance value of the heating pattern was measured again by the four-proved method, the value was 6.55Ω (resistance change rate was 8.0%). Thus, it was possible to obtain the resistance value close to the target value of 6.65Ω.
[0049] It is noted that in the embodiment, only the examples in which the pyrolytic graphite and the boron-containing pyrolytic graphite are used for the conductive heating element are shown. However, when silicon-containing pyrolytic graphite was used, the similar result was obtained.
[0050] It was also confirmed that in the ceramic substrate, the resistance change of the conductive heating element by the high-temperature heat treatment occurred even in alumina other than pyrolytic boron nitride or a nitride aluminum substrate. | 4y
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BACKGROUND OF THE INVENTION
The present invention results from research performed under U.S. Government Contract No. XZ-0-9219 for the Solar Energy Research Institute.
FIELD OF THE INVENTION
The present invention relates to hydrogenated amorphous silicon and more particularly to a method for reactively sputtering a PIN amorphous silicon semiconductor device having partially crystallized P and N layers.
Amorphous silicon has been used in a number of semiconductor devices, the most promising of which is the PIN structure. Such devices were first fabricated by the method of glow discharge decomposition of silane and described in a technical publication by D. E. Carlson, J. Non-Crystalline Solids, 35-36, (1980) p. 707. The P and N layers in this method are deposited by mixing approximately 1 to 2% of B 2 H 6 or PH 3 in the silane discharge. The principal deficiency of this device, as noted by Carlson, is that the P-layer which forms the major semiconductor junction with the I-layer, is both poorly conductive and absorbs the incident light energy without significantly contributing to the collection of photogenerated charge carriers in the device. Because the N-layer absorbs much less light than the P-layer, Carlson has shown that illumination from the N-side leads to higher solar cell efficiency.
A further improvement to the efficiency of this device has been described in a technical publication by Y. Uchida et al., Japanese Journal of Applied Physics, 21, (1982) p. L586. These authors fabricated the N-layer by glow discharge decomposition of a mixture of SiH 4 -H 2 -PH 3 and high power in the discharge. Under these conditions, they claim that the N-layer is partially crystallized (microcrystalline) and therefore it is both highly conductive and highly transparent in the visible part of the spectrum. This type of N-layer is ideal as a "window" material and leads to a 13% improvement in the short-circuit current of the solar cell. The devices reported by Uchida have the configuration stainless steel/PIN/ITO with the P and I-layers being amorphous and the N-layer being microcrystalline.
PIN semiconductor devices have also been fabricated by the method of reactive sputtering and described in a technical publication by T. D. Moustakas and R. Friedman, Appl. Phys. Lett. 40, (1982) p. 515. The I-layer of these devices was fabricated by sputtering from an undoped silicon target in an atmosphere of Argon containing 10-20% H 2 . The P and N-layers were fabricated by adding approximately 0.1 to 1% of B 2 H 6 or PH 3 in the Ar-H 2 discharge. The hydrogen content for the "window" (P-layer) was increased to approximately 20 to 40% in order to improve its transparency to visible light. All three layers (P, I, N) of this device are amorphous.
In view of the improvements of the solar cell efficiency of PIN devices produced by glow discharge decomposition of silane employing a microcrystalline N-contact as a "window" layer, it is important to fabricate such devices by the method of RF sputtering.
SUMMARY OF THE INVENTION
The invention is directed to a method for depositing by RF sputtering an amorphous PIN Semiconductor device, having the "window" (P or N) or both contacts deposited under conditions which lead to partially crystallized (microcrystalline) material. The method of the present invention shall be illustrated and described with respect to a PIN device. It is to be understood, however, that the method of the present invention applies equally well to an NIP device.
A microcrystalline N-layer is deposited by RF sputtering from an undoped silicon target in an atmosphere containing hydrogen, argon and phosphine at a total pressure larger than 20 mTorr with H 2 /Ar>>1 and phosphine content approximately 0.1 to 1% of the argon content. The power in the discharge is adjusted to lead to DC bias target voltage of between -800 to -2000 volts and the substrate temperature to between 200° to 400° C. An intrinsic layer is also reactively sputtered from an undoped target in an atmosphere of 5 to 15 mTorr of argon containing 10 to 20% hydrogen. The target voltage and the substrate temperature are the same as during the deposition of the N-layer. This I-layer is amorphous. A microcrystalline P-layer is reactively sputtered from an undoped silicon target in an atmosphere containing hydrogen, argon and diborane at a total pressure larger than 20 mTorr with H 2 /Ar>>1 and diborane content approximately 0.1 to 1% of the argon content. The target voltage and the substrate temperature vary in the same range as those of the N and I-layers. The contact (P or N) which is deposited on the top of the I-layer is preferably deposited at lower target voltage (˜-800 volts) in order to avoid surface damage of the I-layer. [The three layers are deposited sequentially in three interlocked chambers in order to avoid cross contamination between the layers. If they are deposited in the same chamber the chamber has to be purged and sputter-cleaned between the first doped and the intrinsic layer.] Transparent electrodes and metallic grids are also sputter deposited which permits the entire deposition to be accomplished in one sputtering apparatus and in one vacuum pump-down. When the P and N layers are fabricated in microcystalline form, the PIN solar cells have an open circuit voltage of about 0.1 to 0.20 V higher then entirely amorphous PIN solar cells and 10 to 20% higher short circuit current due to the better blue response of these solar cells.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a greatly enlarged side view of a semi-conductor device constructed in accordance with the teaching of the present invention.
FIG. 2 shows the I-V characteristics of a sputtered PIN solar cell having microcrystalline P and N layers.
FIG. 3 shows the increase (curve -- ) in the collection efficiency in the blue portion of the spectrum of a PIN Cell by using a microcrystalline P-layer for the front contact and a microcrystalline N-layer as the rear contact compared to one (curve -- ) having amorphous P and N-layers.
DETAILED DESCRIPTION OF THE INVENTION
The sputtered amorphous silicon PIN device of the present invention, as illustrated in FIG. 1, includes a substrate 10 which generally comprises a physically supportive substrate for the overlying sputter deposited layers. Substrate 10 includes a major area coating surface which is substantially free from voids or protrusions of the order (in size) of the thickness of the overlying layers to avoid pin holes therethrough.
In one embodiment, substrate 10 may comprise a non-electroconductive material such as glass or ceramic for which an overlying layer of an electroconductive material 11 is required. Alternately, substrate 10 may comprise a metal concurrently serving as a supportive substrate and an electrode contact to the overlying layers. In either instance, the coating surface of the substrate is thoroughly cleaned to remove unwanted contamination of the coating surface. In a preferred embodiment, electrode 10 comprises a metal known to form an ohmic contact to N-doped silicon such as molybdenum or stainless steel for example. In the case where substate 10 comprises a nonelectroconductive material it is preferred that layer 11 comprise a layer of metal known to form an ohmic contact to N-doped microcrystalline silicon; examples are molybdenum or chromium thin films of approximately 1,000 to 2,000 Å thick or a transparent conductive oxide such as ITO, SnO 2 , or cadmium stannate approximately 1000 Å thick.
The substrates are fastened to the anode electrode of a conventional RF diode sputtering unit which is adapted to provide controlled partial pressures of hydrogen, argon, phosphine, and diborane as detailed hereinafter. The term secured is intended in this application to mean both the physical securing of the substrate to the anode electrode and more importantly the electrical contacting of the conducting coating surface to the anode electrode. In this manner, the coating surface is maintained at the approximate electrical potential of the anode electrode. The anode electrode is either electrically grounded or supplied with a positive or negative bias of approximately +50 volts. The sputtering system is further adapted to provide for controlled temperature heating of the substrates. The deposition temperature as recited hereinafter is measured by a thermocouple embedded in the anode electrode.
It is to be recognized that the temperatures recited hereinafter are measured accordingly and the actual temperature of the depositing film may differ.
The sputtering system is evacuated to a base pressure of about 1×10 -7 Torr by conventional mechanical and turbomolecular pumping means. An N-layer of hydrogenated microcrystalline silicon, 12, is sputter deposited by first heating substrate to a monitored temperature ranging from about 200° C. to about 400° C. A sputtering target comprising a poly-crystalline undoped silicon disc about 5" in diameter is secured to the cathode electrode being located about 4.5 cm from the substrate platform (anode electrode). Consistent with the condition H 2 /Ar>>1 and total pressure ≧20 mTorr, as described above, the sputtering atmosphere comprises a partial pressure of hydrogen ranging from about 20 mTorr to about 80 mTorr and argon ranging from about 3 mTorr to about 10 mTorr. For the best microcrystalline material, a preferred combination of parameters should be H 2 /Ar≧10 and H 2 +Ar≧40 mTorr. To dope the hydrogenated microcrystalline silicon layer N an amount of phosphine (PH 3 ) is added to the partial pressures of hydrogen and argon. In one embodiment, the argon source contains 0.2-1 atomic % of phosphine. The sputtering is accomplished at an RF power of about 100 to 200 watts resulting in an induced DC bias of about -800 to -2000 volts relative to the electrically grounded substrate platform (anode). The deposition rate of the films depends on the relative amounts of H 2 to Ar in the discharge. These conditions lead to deposition rates between 10 to 40 Å/sec. These lower deposition rates of the microcrystalline material as compared to amorphous material are caused by the higher concentration of H 2 which leads to the etching of the deposited film and thus competes with the deposition process of silicon. The sputter deposition continues for a time ranging from a minimum of 2.5 min. to about 10 mins., resulting in a thickness of the N-layer, 12, ranging from about 100 angstroms to about 400 angstroms. Alternatively, the N layer can be produced in a graded form extending up to 500 to 1000 Å. This can be accomplished by progressively reducing the amount of PH 3 in the discharge. The substrate heating described heretofore continues throughout the deposition to maintain the monitored substrate temperature within the indicated range. This results in a proper level of hydrogenation of the depositing microcrystalline silicon, which was found to be about 3-4% by unfrared spectroscopy.
An intrinsic layer of hydrogenated silicon 14 is sputter deposited from an undoped silicon target in an atmosphere containing pure argon and hydrogen. This layer 14 is amorphous. The sputtering atmosphere for depositing the intrinsic layer ranges from about 3 mTorr to about 15 mTorr of pure argon and from about 0.3 mTorr to about 1.5 mTorr of hydrogen. The RF power conditions, cathode and anode configuration, and substrate temperature are substantially identical to that described for the sputter deposition of the N-layer. Under these conditions, a layer of intrinsic amorphous silicon ranging from about 0.2 microns to about 1.5 microns in thickness is deposited at a rate ranging from 60 A/min to 1000 A/min.
A P-doped layer of hydrogenated microcrystalline silicon 16 is sputtered deposited from an atmosphere of argon, hydrogen and diborane. Consistent with the condition H 2 /Ar>>1 and total pressure >20 mTorr, as described above, a sputtering atmosphere comprising argon and hydrogen having partial pressures ranging from about 3 mTorr to about 10 mTorr and about 20 mTorr to about 80 mTorr respectively, includes a level of diborane dopant sufficient to dope the microcrystalline silicon P-type. For the best microcrystalline material, a preferred combination of parameters should be H 2 /Ar≧10 and H 2 +Ar≧40 mTorr. In one embodiment, the argon source contains about 0.2 to 1 atomic % of diborane (B 2 H 6 ). The sputtering power conditions, monitored substrate temperature ranges, and configuration of the anode and cathode electrodes are substantially identical to those described for the deposition of the N and I layers. The deposition rate of the film depends on the relative amounts of H and Ar in the discharge. These conditions lead to deposition rates of 10 A/min to 40 A/min. The thickness of the P-layer, as compared to the thickness of the intrinsic and N-doped layers is smaller, ranging from about 80 to about 150 angstroms. As presently understood, the P-layer functions to form a potential barier with the I-layer. The P and N layers fabricated according to the descriptions given above were found by X-ray and Raman spectroscopy to be partially crystallized with crystallite size of 50-60 A. Furthermore, the index of refraction of these P and N layers in the visible spectral region are about 3.0 while that of the amorphous silicon is about 4.0. The P and N layers were also found to be about one half an order of magnitude less absorbing to visible light than the corresponding amorphous layers. In addition, they have conductivities between 1 and 10 (Ωcm) -1 while the corresponding amorphous P and N layers have conductivities of 10 -2 to 10 -3 (Ωcm) -1 . A current collection electrode 18, comprises an electroconductive material which is semi-transparent in the spectral region ranging from about 3,500 angstroms to about 7,000 angstroms, which constitutes the principal absorption region of the underlying amorphous silicon film layers. Further, electrode 18 must form a substantially ohmic contact to the contiguous P-doped microcrystalline silicon. In one embodiment, electrode 18 may comprise a semi-transparent conductive oxide such as indium tin oxide, tin oxide, or cadmium stannate. In such an embodiment, the thickness of the conductive oxide may be tailored to provide an anti-reflection coating to the underlying amorphous silicon surface. These conductive oxides are deposited by RF sputtering from corresponding targets. It is desirable that the oxide be deposited on the solar cell at temperatures between 250° and 300° C. to anneal any induced sputtering damage on the solar cell and to improve the sheet resistance which was found to be about 50Ω/ . The index of refraction of these oxides is about 2 to 2.2. Therefore, the index of refraction of the P and N layers of about 3 is an intermediate value between that of the oxide and that of the I layers. This gradual transition of the indices of refraction is desirable for better collection of light. In an alternative embodiment, electrode 18 may comprise a relatively thin metallic layer, also being semitransparent and forming an ohmic contact to P-doped microcrystalline silicon. An example is platinum.
To further assist in the collection of current generated by the photovoltaic device, a grid electrode 20 may be patterned on the surface of electrode 18. The electroconductive grid, generally configured to minimize the area of coverage and concurrently minimize the series resistance of the photovoltaic cell, may be constructed by several alternate techniques well known in the art.
Those skilled in the art recognize that the use of a glass or other similarly transparent substrate 10, having an transparent electroconductive layer 11 (e.g. ITO or SnO 2 ), permits illumination of the device through the substrate. Furthermore, the deposition sequence of P and N layers may be reversed to deposit a layer of P microcrystalline silicon onto an ITO coated substrate, having the intrinsic and N layers deposited thereupon.
It is to be recognized that the several layers comprising the photovoltaic device described heretofore, may be accomplished by sputtering techniques facilitating the construction of this device in a singular vacuum sputtering unit and in a singular vacuum pump down. It should further be recognized that the sputtering techniques used in the construction of a photovoltaic device of the present invention result in enhanced physical integrity and adherance of the deposited films. The method manifests in an ability to sputter deposit a layer of semi-transparent conductive oxides such as indium tin oxide onto a relatively thin P doped layer, 16, without deteriorating the junction forming characteristics of the underlying silicon layers. Essentially, the cell can be illuminated either from the substrate side or the side opposite the substrate because of the superior properties of the sputtered microcrystalline N and P layers.
EXAMPLE
FIG. 2 shows the I-V characteristics of a sputtered amorphous silicon PIN solar cell structure employing microcrystalline P and N layers. Note that the short circuit current in this device is 13 mA/cm 2 and the open circuit voltage is 0.86 volts. If these numbers are combined with the fill factor of 0.49 (see FIG. 2), the efficiency is between 5% and 6%. The substrate in this structure is mirror polished stainless steel. This substrate was ultrasonically cleaned and degreased before it was fastened to the anode electrode of the previously described diode sputtering unit. The vacuum chamber was evacuated to a base pressure of 1×10 -7 Torr and the substrate was heated to 325° C. The three active layers of the device were deposited under the conditions and order described below:
The partially crystallized N-layer was deposited in an atmosphere of 40 mTorr of H 2 +Ar+PH 3 . The partial pressures of these gases were 36 mTorr of hydrogen and 4 mTorr of argon. The phosphine was contained in the cylinder of argon at a concentration of 0.2 atomic %. Therefore, during the deposition of this layer the ratio of H 2 /Ar was much larger than one and the total pressure was larger than 20 mTorr. Both of these conditions were found to be necessary for the deposition of partially crystallized N-layer. The polycrystalline undoped silicon target, 5" in diameter, was supplied with an RF power of 100 watts leading to a target voltage of -1200 volts. The deposition lasted for 6 min., leading to a film of approximately 200 Å thick. As mentioned earlier, this film has a conductivity of about 10 (Ωcm) -1 and is far more transparent than the corresponding amorphous N-layer.
At this point the substrate with the N-layer was transferred to another clean chamber for the deposition of the intrinsic I-layer. This layer was deposited in an atmosphere of 5 mTorr of Ar+H 2 . The hydrogen content in this discharge was approximately 18% of the argon content. The 5" polycrystalline undoped silicon targe was supplied with an RF power of 80 watts, leading to a bias voltage of -1000 volts. The deposition for this layer lasted 60 min., leading to an I-layer about 4000 Å thick. The substrate temperature during this deposition was maintained at 325° C.
The partially crystallized P-layer was deposited next in an atmosphere of 40 mTorr of H 2 +Ar+B 2 H 6 . The partial pressures of these gases were 36 mTorr of hydrogen and 4 mTorr of argon. The B 2 H 6 was contained in the cylinder of argon at a concentration of 0.2 atomic %. Under these conditions, the P-layer is partially crystallized, having a conductivity of about 2 (Ωcm) -1 and high transparency. The polycrystalline undoped silicon target, 5" in diameter, was supplied with an RF power of 60 watts, leading to a target voltage of -800 volts. The deposition of this layer lasted for 3 min., leading to a P-layer of 100 Å thickness.
At this point the substrate with the three active layers (N,I,P) was moved to another sputtering chamber for the deposition of an ITO (Indium Tin Oxide) layer on the top of the P-layer. This layer was deposited from an ITO target in an atmosphere of argon. The target voltage during this deposition was maintained at -600 volts and the thickness of this layer was chosen to be 600 to 700 Å. A metal grid made of silver was deposited on the top of the ITO.
FIG. 3 shows the increase (curve - - - ) in the collection efficiency in the blue portion of the spectrum of a PIN Cell by using a microcrystalline P-layer for the front contact and a microcrystalline N-layer as the rear contact compared to one (curve - - - ) having amorphous P- and N-layers. | 4y
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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation application of application Ser. No. 13/346,836, filed on Jan. 10, 2012;
BACKGROUND OF THE INVENTION
The present invention is directed to a telescopic flashlight, and, in particular, to such a telescopic flashlight disclosed in U.S. Pat. No. 7,510,295, which patent is incorporated by reference herein, and which discloses a telescopic, collapsing flashlight having an extensible stem with a retractable and bendable flexible member, which allows for hard-to-reach areas and locations to be illuminated. The illuminating structure or device of the flashlight is attached to, and located at, the distal end of the flexible member, and includes a power button. At the distal end of the illuminating body, there is also provided a magnetic collar for use in attracting and holding a metal object during use of the flashlight.
In U.S. Pat. No. 5,951,142 there is disclosed an adjustable illuminating apparatus having an adjustable lighting unit, and which is also provided with an adjustable reflecting mirror unit mounted at the end of the apparatus, with the light from the lighting unit impinging on the mirror and being reflected thereby. The reflecting mirror unit is mounted to the end of the apparatus via mating threaded parts.
In published U.S. Application Number US2005/0201085, there is disclosed a telescopic flashlight apparatus having at one end thereof a pivotal mirror unit for reflecting the light emanating from the lighting unit to various locations. This mirror unit is cumbersome, and difficult to attach and remove.
SUMMARY OF THE INVENTION
It is the primary objective of the present invention to provide a telescopic, collapsible flashlight apparatus that includes a universally adjustable inspection mirror unit for reflecting the light of the lighting unit over a universal range, which mirror unit is readily and easily attached and detached from the distal end of the flashlight apparatus via a mounting collar having an annular metallic mounting ring that is magnetically retained by means of an annular magnet affixed to the distal end of the apparatus where the lighting or illuminating device is located, which mounting collar itself is rotatable relative to the distal end of the flashlight apparatus in order to provide two degrees of freedom of rotational motion of the mirror proper.
It is also the primary objective of the present invention to provide such a telescopic flashlight apparatus with a distal, adjustable mirror unit that is itself removably detachable, such that the mirror proper may be attached and re-attached to the mounting collar at will, so that when the mirror proper is not needed for directing the light from the lighting unit to hard-to-see or get-at places or locations, it may be removed from the metallic mounting collar, so that it does not interfere with the normal and average use of the flashlight apparatus.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be more readily understood with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of the telescopic flashlight device with universally-adjustable mirror unit of the invention;
FIG. 2 is a perspective view of the universally-adjustable mirror unit of the flashlight device of FIG. 1 and showing various positions it may be assume in a first plane;
FIG. 3 is a perspective view similar to FIG. 3 but showing the universally-adjustable mirror unit pivoted to various positions via a first pivot in a second plane;
FIG. 4 is a perspective view similar to FIG. 3 but showing the universally-adjustable mirror unit pivoted to various positions via a second pivot in the second plane;
FIG. 5 is an assembly view, in perspective, showing the telescopic flashlight device with universally-adjustable mirror unit of FIG. 1 ;
FIG. 6 is an assembly view of the universally-adjustable mirror unit of the invention; and
FIG. 7 is a transverse cross-sectional view of the assembled universally-adjustable mirror unit.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings in greater detail, the telescopic flashlight device with universally-adjustable mirror unit is indicated generally by reference numeral 10 . The basic telescopic flashlight is that disclosed in U.S. Pat. No. 7,510,295, which patent is incorporated by reference herein. The telescopic, collapsing flashlight 10 includes a main, hollow, cylindrical handle, body portion or casing 12 , used for gripping the flashlight, and in which is received a series of collapsing, hollow, telescoping elements or sections 14 , 16 , 18 , 20 , and 22 . Each telescopic element 14 , 16 , 18 , 20 , and 22 is collapsible into the immediate-adjacent element closer to the main body portion or housing 12 , in the manner depicted in FIG. 1 , for storage, and for removal therefrom for expansion and use. The degree to which the telescoping elements are pulled out is variable so that the flashlight may be used in all environments. The end of the main body portion is provided with a enlarged head or section 12 ′, to which is secured a magnet for attracting and holding metal objects.
At the end of the telescopic section 22 there is provided a flexible, bendable member or section 26 which is collapsible into the telescopic section 22 , and to the end of which is attached or mounted an illuminating or lighting unit or device 30 . The illuminating device 30 comprises a hollow main housing 32 serving as a battery or power-cell compartment, a push-button switch 34 , or the equivalent thereof, and a removable bulb-fixture 38 ( FIG. 5 ) containing one or more halogen lighting bulbs or LCD's. The distal end 38 ′ of the removable bulb-fixture 38 also mounts a forwardly-facing, annular magnet, such as magnet-ring 40 , by which objects may be picked up and held.
The annular magnet 40 is used to removably, temporarily and rotatably mount a universally-pivotal reflection mirror unit 44 . The universally-pivotal reflection mirror unit 44 is comprised of a removable mounting collar or annular ring-element 46 , defining an inner, circular main portion 48 defining an exteriorly-located or outer annular surface section, which is substantially circular in shape that defines an outer or outwardly-facing opening 50 . To the interior-facing portion of the exteriorly-located or outer annular surface section is mounted an annular element or ring 54 made of magnetic material, such as ferrous metal, which is attracted to, and held by the, annular magnet 40 . The inner or inwardly-facing opening 56 of the annular ring-element 46 has a diameter slightly larger than the diameter of the distal end of the removable bulb-fixture 38 , so that the annular ring-element 46 may be telescopingly mounted thereover, and held removably in place thereat, by means of the annular magnet 40 magnetically retaining the annular ring-element 46 via the metallic ring or annular element 54 , whereby the entire universally-pivotal reflection mirror unit 44 is rotatable in a first degree of rotational motion about the end of the flashlight. It is noted that the central or inner opening of the annular ring-element 46 has a diameter less than the diameter of the distal end of the removable bulb-fixture 38 , whereby the interior-facing portion of the metallic annular ring 54 abuts against the annular end-surface distal end 38 ′ of the removable bulb-fixture 38 in face-to-face contact with the annular magnet 40 to allow for the mounting thereto. The material from which the annular ring element 46 is made is preferably plastic providing a low coefficient of friction, which readily allows the rotation thereof about the distal end 38 ′ of the illuminating device 30 , which is also made of plastic having a low coefficient of friction. The facing and contacting surfaces of the annular magnet 40 and the metallic annular ring 54 also offer a low coefficient of friction, whereby no obstruction to the rotation of the mounting annular ring-element 46 exists. Alternatively, the annular ring 46 may be made entirely of a low-coefficient-of-friction magnetic material, such as ferrous metal, which obviates the need for the metallic annular ring 54 .
The removable mounting collar or annular ring-element 46 is also provided with an eccentric or protruding section 58 defining a through-opening or hole 60 . The opening 60 has a first outer portion 60 ′ that is preferably hexagonal in shape for part of the depth of the opening 60 , and a second inner portion 60 ″ that is circular in shape for the remainder of the depth thereof. Mounted in the circular portion 60 ″ is a circularly-shaped magnetic rod or post-element 64 , as best seen in FIGS. 6 and 7 .
The universally-pivotal reflection mirror unit 44 also consists of the main mirror-portion 68 , which contains the mirror-element proper 70 , which is preferably circular in shape. The circular-shaped mirror 70 has a mounting eccentric or ear 72 defining a bottom pivot shaft or post 72 ′ that is pivotally mounted at one end 76 ′ of a mounting bracket 76 , in a conventional manner; the mirror unit is allowed a second degree of rotational motion different from the first degree of rotational motion provided by the annular ring-element 46 . To the other end 76 ″ of the mounting bracket 76 is pivotally mounted a metallic mounting pin or shaft 80 , made of ferrous metal or the like, which defines a hexagonally-shaped main shaft portion 80 ′ which is partially receivable in the first, outer hexagonally-shaped portion 60 ′ of the opening 60 , whereby the metallic mounting pin or shaft 80 , and thus the mirror-element proper 70 , are removably mounted to the mounting collar or annular ring-element 46 , and where the mirror unit is also allowed additional degrees of rotational motion via the spherical or ball joint at the upper end of the pin 80 . Thus, the universally-pivotal reflection mirror unit 44 is removable from the illuminating or lighting unit or device 30 in two ways or sections: The first by means of the metallic collar, or an annular element or ring 46 , by which the entire mirror unit 44 is removable, and the second by means of the metallic mounting pin or shaft 80 , by which part of the mirror unit 44 is removable, whereby differently-shaped or sized mirrors 70 may be mounted to the illuminating device. For example, a prism mirror, disclosed in U.S. Pat. No. 6,210,009, may be attached to the illuminating apparatus, which prism mirror displays a non-inverted image of the object or objects, being viewed in the proper sense and handedness.
While the universally-pivotal reflection mirror unit 44 has been disclosed for use and removable attachment to a telescopic, collapsing flashlight, it may be used in all types of flashlights incorporating an annular magnet at the distal end of the lighting unit itself, or at the distal of another section of the flashlight. Moreover, the universally-pivotal reflection mirror unit 44 may incorporated into other lighting devices not considered to be a flashlight, as long as it incorporates a magnetic ring or magnetic, in a manner equivalent to the mounting of the universally-pivotal reflection mirror unit 44 .
It is also noted that instead of the forwardly-facing annular magnet 40 located on the front surface of the illuminating device 30 , a collar-magnet that circumferentially surrounds the end 38 ′ thereof may be used, in which case the annular element or ring 46 would be located or mounted to interior annular rim-surface thereof for face-to-face contact with the collar-magnet.
While a specific embodiment of the invention has been shown and described, it is to be understood that numerous changes and modifications may be made therein without departing from the scope and spirit of the invention. | 4y
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CLAIMS OF PRIORITY
This application is a Continuation-in-Part of U.S. patent application Ser. No. 12/529,625, filed on Apr. 15, 2010, which is the national stage filing of International Patent App. No. PCT/US08/75374 and claims priority to U.S. Provisional App. No. 60/970,655, filed on Sep. 7, 2007, U.S. Provisional App. No. 60/974,909, filed on Sep. 25, 2007, U.S. Provisional App. No. 60/978,932, filed on Oct. 10, 2007, U.S. Provisional App. No. 61/012,334, filed on Dec. 7, 2007, U.S. Provisional App. No. 61/012,337, filed on Dec. 7, 2007, U.S. Provisional App. No. 61/012,340, filed on Dec. 7, 2007, and U.S. Provisional App. No. 61/037,032, filed on Mar. 17, 2008.
This application further claims priority to U.S. patent application Ser. No. 12/529,617, filed Sep. 2, 2009, which is the national stage filing of International Patent App. No. PCT/US08/075366, and claims priority to U.S. Provisional App. No. 60/970,655, filed on Sep. 7, 2007, U.S. Provisional App. No. 60/974,909, filed on Sep. 25, 2007, U.S. Provisional App. No. 60/978,932, filed on Oct. 10, 2007, U.S. Provisional App. No. 61/012,334, filed on Dec. 7, 2007, U.S. Provisional App. No. 61/012,337, filed on Dec. 7, 2007, U.S. Provisional App. No. 61/012,340, filed on Dec. 7, 2007, and U.S. Provisional App. No. 61/037,032, filed on Mar. 17, 2008. All the preceding applications are incorporated by reference in their entirety.
FIELD OF THE INVENTION
The invention relates to a fluid composite, a device for producing the fluid composite, and a system for producing an aerated fluid composite therewith, and more specifically a fluid composite made of a fuel and its oxidant for burning as part of different systems such as fuel burners or combustion chambers and the like.
BACKGROUND
Mixing of components is known. The basic criterion for defining efficiency of a mixing process relates to those parameters that define the uniformity of a resultant mix, the needed energy to create this change in parameters, and the capacity of the mix to maintain those different new conditions. In some technologies, such as the combustion of a biofuel, an organic fuel, or any other exothermic combustible element, there is a desire for an improved method of mixing a combustible element with its oxidant or with other useful fluids as part of the combustion process.
Several technologies are known to help with the combustion of fuel, such as nozzles that spray a fuel within the oxidant using pressurized air, eductors, atomizers, or venturi devices that are sometimes more effective than mechanical mixing devices, these devices generally act upon only one components to be mixed (i.e. the fuel or the oxidant) to recreate a dynamic condition and an increase of kinetic energy. Engines such as internal combustion engines burn fuel to power a mechanical device. In all cases, these engines exhibit less than one hundred percent efficiency in burning the fuel. The inefficiencies result in a portion of the fuel remaining non-combusted after a fuel cycle, the creation of soot, or the burning at less than optimal rates. The inefficiency of engines or combustion chamber conditions can result in increased toxic emissions into the atmosphere and can require a larger amount of fuel to generate a selected level of energy. Various processes have been used to attempt to increase the efficiency of combustion.
In chemistry, a mixture results from the mix of two or more different substances without chemical bonding or chemical alteration. The molecules of two or more different substances, in fluid or gaseous form, are mixed to form a solution. Mixtures are the product of blending, mixing, of substances like elements and compounds, without chemical bonding or other chemical change, so that each substance retains its own chemical properties and makeup. Composites can be the mixture of two or more fluids, liquids, or gas or any combination thereof. For example a fluid composite may be created from a mixture of a fossil fuel and its oxidant such as air. While one type of composite is described, one of ordinary skill in the art will recognize that any type of composite is contemplated.
Another property of composites is the change in overall properties while each of the constituting substances retains their own properties when measures locally. For example, the boiling temperature of a composite may be the average boiling temperature of the different substances forming the composite. Some composite mixtures are homogenous, while other are heterogeneous. A homogenous composite is a mixture whose composition locally cannot be identified, while a heterogenous mixture is a mixture with a composition that can easily be identified since there are two or more phases present.
What is needed is a new fluid composite having desirable overall properties and characteristics, and more specifically a new fuel composite with improved property of enhance fuel burning, burn rates, greater heat production from the fuel, better spread of the thermal distribution in an environment, and other such properties. Further, fuel is often sent to a combustion chamber using a pump, since fuel is a liquid it is mostly incompressible. Compressibility allows for compression and expansion and is often desirable. Further, incompressible fluids are subject to great changes in internal pressure when flow is disrupted or pumping is not uniform. What is needed is a fluid composite capable of giving compressibility to a fuel without the disadvantages associated with compressible gases.
SUMMARY
The current disclosure relates to a new fluid composite, a device for producing the fluid composite, and a system of use therewith, and more specifically a fluid composite made of a fuel and its oxidant for burning as part of different systems such as fuel burners, where the fluid composite after a stage of intense molecular between a controlled flow of a liquid such as fuel and a faster flow of compressed highly directional gas such as air results in the creation of a three dimensional matrix of small hallow spheres each made of a layer of fuel around a volume of pressurized gas. Since the fuel composite is compressible, external conditions such as inline pressure can warp the spherical cells into a network of oblong shape cells where pressurized air is used as part of the combustion process. In yet another embodiment, additional gas such as air is added via a second inlet to increase the proportion of oxidant to carburant as part of the mixture.
BRIEF DESCRIPTION OF THE DRAWINGS
Certain embodiments are shown in the drawings. However, it is understood that the present disclosure is not limited to the arrangements and instrumentality shown in the attached drawings.
FIG. 1 is a cross-section of a device for producing a fluid composite.
FIG. 2A is diagram of a fuel cell as part of the fluid composite produced by the device shown at FIG. 1 according to an embodiment of the present disclosure.
FIG. 2B is two dimensional representation of a network of fuel cells as shown at FIG. 2A as part of the fluid composite produced using the device shown at FIG. 1 according to an embodiment of the present disclosure.
FIG. 2C is a close us view of an expansion area for the first and second fluids where cells of the fluid composite as shown at FIG. 2B are produced within the device for producing a fluid composite as shown on FIG. 1 according to an embodiment of the present disclosure.
FIG. 2D is a two dimensional representation of the network of fuel cells as shown at FIG. 2B as part of a compressed fluid composite produced using the device shown at FIG. 1 according to an embodiment of the present disclosure.
FIG. 3 is a cross-section of the device for producing a fluid composite of FIG. 1 where the outlet of the device includes an X shape concentrator for the fluid composite according to another embodiment of the present disclosure.
FIG. 3A is a view from FIG. 3 taken at line 3 A- 3 A illustrating a possible X shape gas inlet system according to an embodiment of the present disclosure.
FIG. 3B is a view from FIG. 3 taken at line 3 B- 3 B illustrating a possible X shate fluid composite concentrator.
FIG. 4 is a cross-section of the device for producing a fluid composite of FIG. 3 including a post production chamber used to further alter the fluid composite according to another embodiment of the present disclosure.
FIG. 5 is a cross-section of the device for producing a fluid composite of FIG. 1 including an acceleration nozzle for entry of a secondary fluid into the fluid composite according to an embodiment of the present disclosure.
FIG. 6 is a cross-section of the device shown at FIG. 5 further including a secondary fluid inlet according to an embodiment of the present disclosure.
FIG. 7 is a cross-section of the device for producing a fluid composite of FIG. 5 wherein the acceleration nozzle includes conical shape vortex channels.
FIG. 8 illustrates an integrated functional system where the device for producing a fluid composite of FIG. 1 is used according to an embodiment of the present disclosure.
FIG. 9 illustrates the different phases of dynamic evolution of the process of formation of the fluid composite according to the device shown at FIG. 1 according to an embodiment of the present disclosure.
FIG. 10 illustrates an integrated functional system where the device for producing a fluid composite of FIG. 5 is used according to another embodiment of the present disclosure.
FIG. 11 illustrates an integrated functional system where the device for producing a fluid composite of FIG. 7 is used according to another embodiment of the present disclosure.
FIG. 12 illustrates with greater detail the mechanism of formation of the fluid composite as illustrated at FIG. 2D .
FIGS. 13A-13D are diagrams of fuel from the parent application given as FIGS. 15A to 15D .
DETAILED DESCRIPTION
For the purposes of promoting and understanding the principles disclosed herein, reference is now made to the preferred embodiments illustrated in the drawings, and specific language is used to describe the same. It is nevertheless understood that no limitation of the scope of the invention is hereby intended. Such alterations and further modifications in the illustrated devices and such further applications of the principles disclosed and illustrated herein are contemplated as would normally occur to one skilled in the art to which this disclosure relates.
The following specification includes by reference all figures, disclosure, claims, headers, titles, of International Applications Nos. PCT/US08/75374, filed Sep. 5, 2008, and entitled “Dynamic Mixing of Fluids”, and PCT/US08/075366, also filed on Sep. 5, 2008, and entitled “Method of Dynamic Mixing of Fluids” along with nationalized U.S. applications Ser. No. 12/529,625, filed Sep. 2, 2009, and entitled “Dynamic Mixing of Fluids”, and Ser. No. 12/529,617, filed Sep. 2, 2009, and entitled “Method of Dynamic Mixing of Fluids.”
The parent application shows as what was previously FIGS. 15A to 15D . FIG. 13A shows the volumetric structure after the first stage of activation, when the volume made of foam bubbles have not started to be transformed in space of the fuel pipeline and are as though pressed to each other. FIG. 13B shows the structure when the bubbles are being transformed in the fuel mix and separate from each other. FIGS. 13C and 13D show the internal processes in the activated volume of a fuel mix as it moves in the fuel pipeline. This process shows how volumetrically, small spheres are formed and how as the pressure of the gas inside of the sphere changes, the thickness of the fuel shell thins. This process as illustrated is found at zones 906 to 909 as shown at FIG. 9 , greater detail is provided below.
In general, as shown at FIGS. 2A-D , micro-bubbles of fluid are formed and include a core of compressed gas 201 surrounded by a shell of liquid such as fluid or fuel 202 or a shell made of fuel mixed with another liquid such as water. A new foam-like composite called herein the fluid composite 1 is formed including a very large number of very small cells 200 each with a very large number of very small compressed gas cores 201 . The cells are small and numerous and are formed as part of the fluid composite 1 in a very high energy state with dynamic and kinetic energy. The whitish foam of micro-bubbles 200 also called the fluid composite 1 , the fluid and the gas are energized and dynamic. While this disclosure is directed to the creation of any fluid composite 1 made of imbedded pressurized compressed gas 201 core over a shell 202 , having different dynamic components, in one embodiment, the composite is a fuel composite 1 where the liquid is fuel and the gas is air needed to burn the fuel. Within this disclosure, while the term fluid composite 1 is used, one of ordinary skill in the art will understand that the composite 1 can be made of any liquid or liquids mixed in with gas for any commercial application. As a way of a non limiting example, water for irrigation and plant nourishment can require aeration to help with seeping and plant absorption. The water may also require mixing with a fraction portion of fertilizer.
In a fluid composite 1 example, the creation and the merger of a fixed fraction of gas into the liquid is based on a stoichiometric ratio of air to fuel exists where burning is optimal. For some applications, a fraction of this air may be imbedded into the fluid composite 1 to enhance the properties of the fuel. In one example, 10%, 20%, or even 30% of stoichiometric air in weight can be merged into the fuel as part of the fluid composite 1 . The density of air at ground level is approximately ρ air =0.0012 kg/l while the density of gasoline is approximately ρ gz =0.703 kg/l and diesel ρ dz =0.85 kg/l.
With a stoichiometric ratio for diesel fuel to air of 14.6 to 1 and for gasoline of 14.7 to 1, the ratios at the above suggested gas to liquid ratio will vary from about 1.47 to 1 (e.g. 10% or 14.7 to 1) to 4.38 to 1 (e.g. 30% of 14.7 to 1). For the ratio to be 10%, a quantity of 0.085 kg/l must be inserted, or approximately 70.3 liters of air per liter of fuel. At a level of 20% in weight of air, 140.6 liters of air must be mixed in the fuel, and at 30% a quantity of 210.9 liters of air must be inserted into 1 liter of fuel. These values are only illustrative of possible ratios and other ratios are contemplated within the acceptable parameters of the fluid composite 1 .
At these volumetric ratios, for every 1 liter of fuel, 70.3 to 210.9 liters of air are mixed in the fluid composite 1 . Since the fluid composite 1 is a pressurized medium, and that only the gas portion of the fuel cells 200 is compressible (at pressures below 1000 bars), a fluid composite at 17 bars of pressure and a ratio of a 10% mix will correspond to a volume of gas of 4.14 liters of pressurized gas cells 201 inside of a volume of 1 liter of fuel (i.e. 70.3 liters/17 bars). While some ratios are given, what is contemplated is the merger of any ratio of air into the fluid composite either at initial stages of formation or at a second stage after the first fluid composite has been prepared.
The size of the micro-bubbles can also vary based on a plurality of characteristics and components of the apparatus for the creation of the fluid composite 1 as shown at FIG. 1 . Fluid viscosity, surface tension, the temperature, the speed, the pressure, to kinetic energy, are only a small fraction of the different parameters that play a role into the determination and control of a created by a device with small channels 115 where gas flows of a thickness of 5 to 50 μm. Small bubbles of a diameter of 5 to 50 μm are created as shown on FIGS. 1 , and 2 D. Once again, the size of these channels 115 is only illustrative of one contemplated embodiment, for one type of fluid to create one type of fluid composite 1 with unique properties.
These sizes of bubbles 201 correspond for example to an internal radius (r g ) of small spheres of 2.5 microns 25 microns. The absolute volume of gas (V g ) is given by V g =P*(4/3)πr g 3 where P is the pressure inside the sphere. V g can be calculated to be in a range for channels 115 of 5 to 50 μm from V g =65.5*P to 65,500*P μm 3 . In a network structure where cells are arranged as shown in the configuration of FIG. 2B , the volume of fuel (V f ) in the shell surrounding a single bubble is V f =(4/3)πr f 3 −V g /P where r f is the radius of the sphere of liquid and V g is the volume of a sphere of gas. As shown on FIG. 2B , in one embodiment, the shell of the bubbles have a thickness in proportion with the thickness of gas inside the bubble (i.e. where r f ˜2r g ). In such a sample case, V f =1151 to 524,000 μm 3 . While one ratio of thickness of the fuel 202 over the size of the gas 201 is shown and used to help described the fluid composite 1 , one of ordinary skill in the art will understand that fluid composites 1 can be produced having a very wide range of geometries based on the evolution, calibration, of different properties, such as the ratio of the flow rate of incoming gas to the flow rate of incoming liquid, the ratio of volume at the different phases alongside the device shown at FIG. 1 , etc.
Returning to the above example, in order to obtain stoichiometric gas to liquid ratio of 10%, i.e. a fluid composite having a volume of gas of 4.14 liters the volume of liquid over the volume of fuel is taken to be V g /V f =4.14 where for example a 5 μm gas bubble is used, a pressure of 17 bars=Vf*4.14/Vg so a ratio of 1151*4.14/65.5=4.10 is calculated. With a fixed internal bubble of 5 μm, with a reverse calculation we can determine volume of fluid of 268.5 μm 3 and thus determine a radius for the external shell of fuel of 9.75 μm.
Within the confines of testing, in one embodiment, at a stoichiometric air to fuel ratio of 10%, the pressure of the fluid composite is 17 bars for an air entry of 45 bars, for a ratio of 20%, the pressure rises to 35 bars, and for a ratio of 30% the pressure becomes 50 bars for the same air entry pressure. This calculation is a sample calculation and one of ordinary skill in the art will recognize that the thickness of the outer shell of liquid may vary based on a plurality of static and dynamic conditions created within the device as shown at FIG. 1 .
A volume of 1 liter of fluid represents a volume 1×10 15 μm3 which can contain up to 1.8×10 9 cells of a volume of 5.24×10 5 cubic micrometers. The inventor has calculated that in one embodiment, the fluid composite had a density of approximately 2.7×10 7 cells/l. While FIG. 2B teaches a fluid composite where each cell 200 touches the adjacent cell, the fluid composite 1 remains a fluid composite even if the density of cells within the composite drops. For example, the inventor has determined that at density concentrations of 1.5% of the maximum cell density, the fluid composite 1 remains a fluid composite and the associated properties.
Further, in order for the micro-bubble to remain stable for a length of time prior to entry of the micro-bubble into a combustion chamber, the shell of the liquid surrounding the compressed gas is thick enough to prevent the micro-bubble from bursting. In a dynamic mixture, the energy stored within the composite fluid in the form of Brownian movement must first be reduced greatly before the bubbles can collapse. In a regular flow, the fluid molecules in the static walls around pockets of gas thins down as the fluid migrates down under the force of gravity. The walls thin up to a value equivalent to the surface tension forces within the liquid. In a stable flow made of micro-bubbles, an equilibrium must be such that surface tension forces of the liquid shell of a bubble is sufficient to prevent a bubble to collapse with an adjacent bubble having similar properties. Small liquid droplets such as the micro-bubbles are describes and defined by the Young-Laplace equation:
Δ
P
=
γ
(
1
R
x
+
1
R
y
)
Where γ is the surface tension of the external liquid shell of a bubble, R x and R y are curvature radius in X and Y axis respectively, and ΔP is the pressure difference in bars between the internal and the external of the bubble. For the interface water/air at room temperature, γ is approximately 73 mN/m. For an interface between most fuel/air the surface tension is in the range of γ=20 to 40 nM/m. For the micro-bubbles to maintain coherent in a network of cells as shown on FIGS. 13A to 13D , the pressure variation between the inside portion of the bubble and the outside must be coherent.
For droplets of water at standard room temperature and pressure, internal pressure of the bubble cannot rise above 0.0014 bar for a bubble of 1 mm in radius, 0.0144 bar for a bubble of 100 μm, 1.43 bar for a bubble of 1 μm in radius, and 143 bar for a bubble of 10 ηm in radius. In the above example where the surface tension fuel/air is approximately half of the surface tension as the water/air figure, these values are taken to be half of the listed values. These values do not take into effect that the bubbles operate in a fixed volume of incompressible liquid. In a fixed volume area such as the area within a pipe, the effect of small bubble walls collapsing into a single larger bubble, thus breaking the fluid composite would result in a reduction of the surface between the liquid and the gas, an increase in the compactness of the liquid, and thus a diminution of the internal pressure of the gas.
At equilibrium, the fluid composite is in a state where surface tension is such that the pressure difference between the inside of the bubbles when compared to the pressure inside the incompressible fluid acting on the outside of the bubbles is inferior to the Young-Laplace value. At these values, the collapse of a bubble no longer results in a negative value of the Gibbs free energy per unit area.
FIG. 2A shows a gaseous compressed kernel or cell 200 of a fluid composite 1 as shown on FIG. 2B . Each cell 200 as shown includes a compressed gas center 201 surrounded by a shell of incompressible liquid 202 . Shells are held in shape under the external pressure of the fluid composite 1 and in situations where the pressure is uniform in the fluid composite, the structure of the cell 200 is spherical. d 2 illustrates both the external diameter of the liquid cell 200 and the distance between centers of adjacent fuel cells 200 . FIG. 2C illustrates a situation where pressure in the fluid composite 1 is not uniform. The illustration is of a slice in thickness of oval shape cells 200 where the distance in one direction remains d 2 , but is compressed in the other direction to ½ of d 2 . In this context, the distance between centers of two adjacent cells is only ¾ of d 2 . Pressure as shown on FIG. 2C is greater in the horizontal axis by a factor of 2. In one contemplated embodiment, the pressure is caused by external sources such as the pressure of the fluid entering the fluid composite device as shown on FIG. 1 and the like. The fluid composite 1 as shown, unlike the liquid, is compressible in part. The partly compressible nature the fluid composite allows for the composite to evolve past structures of variable geometries and expand/contact locally in yet another advantageous property of the fluid composite 1 .
FIG. 2D shows a portion of the device for the production of the fluid composite 1 as shown at FIG. 1 where the gaseous fuel cells 201 are dynamically being created. FIG. 12 shows an illustration to help understand the interface where the gas cells 201 connect with the activated liquid or gasified liquid portion. Returning to FIG. 2D , air is accelerated and split into small linear cannels 115 . The gas as shown is pushed at a speed where it becomes fully turbulent. In addition to molecular movement and linear average displacement of the gas molecules, small vortices structures are created in the flow creating small circulating structure within the gas at the area of release as shown. These vortices have the pressure of the gas within the channel 115 and store dynamic and kinetic energy in surplus of linear kinetic energy. The molecules of gas arrange in what is described as a dynamic evolution. In one embodiment, the dynamic evolution is a series of vortices where the gas is arranged in structures with rotational energy. Other structures and movements of the gas is contemplated as part of the dynamic evolution.
Once gas as part of these structures leave the channels 115 , they have strong dynamic and turbulent activity. Their coherent structure has a average diameter of d 1 shown to be the diameter of the channel 115 corrected by the depression ratio created within a ring channel 113 . The illustration shows in a simplified fashion how the vortices align along the wall and move up in the ring channel 113 but this alignment is shown for illustration purposes only, the cells 201 already with turbulent movement move in this area in a turbulent fashion under a high rate of speed that is equal to the flow of speed of the fluid composite 1 in the device. The distance between the two coaxial reflectors between the hydraulic and the pneumatic sections 110 is shown with a thickness of H creating a turbulent fluid flow of thickness H. In one embodiment, the thickness H is in the range of 5 to 100 microns, in another embodiment, H is in the range of 10 to 50 microns but thicker ranges such as 100 to 500 microns or even greater are also contemplated. The liquid accelerated and having highly turbulent and dynamic velocity is then projected into the ring channel 113 area where it expands in the increased volume.
FIG. 12 shows how the fluid 1208 may expand to encompass the entire area 1209 considered to be a local ring zone between a hydro-dynamical area and the aerodynamic area where both streams 110 , 115 travel. The pressure varies within the area 1209 and as a consequence, vortex bubbles are created at 1206 and travel upwards to a zone of settled low pressure and high linear speed 1207 before entering a zone 1212 of low pressure and linear movement where the streams merge to form the fluid composite 1 and settles into a channel 123 . The fluid when released at 1208 , is turbulent and dynamic.
At 1210 , an elastic resistance wave is shown where compressed cells 1212 connect with the fluid 110 to create a network of fast moving cells as part of the fluid composite 1 as shown with greater detail at FIGS. 2A-C . One of ordinary skill in the art will understand that while a regular array of cells is shown, each with a gas center 201 surrounded by a shell of incompressible liquid 202 , the energy poured into the creation of the fluid composite 1 is greater and much of the energy remains stored as dynamic elements within the fluid composite 1 . For example, the different cells 1211 shown on FIG. 12 have relative movement and translate, move and shake as would molecules based on a Brownian movement. The gas within the gas center 201 also retains kinetic and dynamic energy, and the fluid also moves turbulently between the pockets of compressed gas.
In an embodiment, the energy is sufficient to help dilute a large fraction of gas molecules, such as gas of nitrogen from the air into the fluid. In another embodiment, the energy is sufficient to break chemical bonds in water and in air and create chemical radicals that can reattach in a plurality of useful ways. For example, if the fluid and the gas are at different temperatures, the resulting mixture may be at the average temperature of the input fluids but a higher energy fluid can be used to help promote nitrogen dilution, chemical reactions, or even cracking of the water for hydrogen ion production.
What is shown and described is a pressurized fluid composite 1 within a vessel such as an external case 106 shown in one embodiment as a portion of a cylindrical pipe. In one embodiment, the external case 106 is a pipe of uniform diameter. Fluid as shown on FIG. 1 enters at 101 and the fluid composite 1 exits at 126 as the stabilized fluid composite 1 on the right of the device. The fluid composite 1 is made of a network of fuel cells 200 in dynamic contact with each other as shown at FIG. 2B or even FIG. 12 . The structure includes a plurality of fuel spheres or fuel cells 200 each multilevel fuel sphere including a core of compressed gas 201 in dynamic evolution, and a shell 202 surrounding the core of compressed gas 201 made of a liquid in dynamic movement. The dynamic contact of fuel cells shown as a neatly packed array of cells 200 is a turbulent displacement of adjacent and connecting cells 200 in a three dimensional environment moving in relation to each other. The dynamic movement of the liquid of the shell 202 of each cell 200 is a turbulent movement of liquid molecules within the thickness of the shell 202 , and the dynamic evolution of the compressed gas 201 is a turbulent movement with vortices.
Within the scope of this disclosure, the term dynamic as part of the expression dynamic contact, dynamic movement, dynamic evolution, or any other expression is to be read and understood as an open handed word to include in addition to any ordinary meaning the fact the different molecules, particles, and constituents of a fluid or gas have a higher level of energy and that as a consequence the molecular agitation, either in term of the linear velocity, angular velocity, spin, Brownian movement, or even temperature are greater than a non dynamic state in contrast to a static state that is non dynamic. The term dynamic include kinetic energy, positive enthalpy changes, positive entropy changes, etc.
In another embodiment, the turbulent displacement is a Brownian movement, a movement that seemingly appears random but is a continuous-time stochastic process. In another embodiment, the fluid composite 1 is made of an incompressible liquid such as a hydrocarbon based fuel and the gas is compressed air. A ratio of the volume of the core of compressed gas over the volume of the fuel cells is 10% to 30% of the stoichiometric air, or a ratio of 1.47 to 4.38 to 1 where stoichiometric ratio is 14.7 of air over fuel and 10% is 1.47 time the volume of air to fuel.
FIG. 1 shows a device 100 for the production of a fluid composite 1 . This device is explained partly in U.S. under applications Ser. No. 12/529,625, filed Sep. 2, 2009, and entitled “Dynamic Mixing of Fluids”, and Ser. No. 12/529,617, filed Sep. 2, 2009, and entitled “Method of Dynamic Mixing of Fluids” both applications are incorporated by reference in their entirety. This device 100 is shown with a plurality of different embodiments at FIGS. 3 to 7 , and is shown as part of a system for the production of a fluid composite at FIGS. 8 to 11 . This device 1 is used to conduct the dynamic mixing and the production of a fluid composite 1 for a plurality of uses including but not limited to the injection of aerated and compressed fuel into an injection chamber of a combustion cycle.
The gas serving as the oxide must be brought in immediate contact with the fuel for optimum combustion of the fuel. When compressed gas 201 as shown on FIG. 2 is released into a non-compressed area, such as a combustion chamber or any other opened area, the gas will immediately expand to reach atmospheric pressure by increasing in size in proportion with its pressure. The external shell 202 under the expansion force, will rip apart the fuel and create a very uniform mist of fuel where combustion is enhanced. High efficiency in fuel burning corresponds to high efficiency in burning of thermal equipment. In a diesel type fuel, greater burning and cleaner burning rates can result from using the composite fuel 1 .
A larger quantity of compressed air, up to 20 times more can be used as carburant of the diesel fuel. The volume of the fluid composite 1 can be increased several times fold, for example the volume of gas reaches for diesel up to 20 times the volume of fuel. Pressure can also be increased during the process of aeration or formation of the fluid composite 1 by adding pressurized gas to an already pressurized inlet of liquid. In one embodiment, the linear speed of the composite fuel 126 over the arrival fuel 101 as shown on FIG. 1 can be up to 20 to 1 or a proportion of the aeration ratio. Pressure can be increased up to five times, the output flame created by the release of the composite fuel 1 in an open area can be increased multiple times because of the added pressure and internal expansion. In one embodiment, an increase in length of a torch in a flame in a burner of 3× is measured. The volume of flame of the fuel is also increased with the same proportion. As a result of greater and cleaner combustion using the fluid composite 1 over ordinary fuel and the lesser the release of waste such as NO x , CO, CO 2 , and soot particles.
The fluid composite 1 is a fuel with new properties. Adding gas does more than create a dual state mixture. The fluid composite 1 has a new physical structure, a new dynamic state that is compressible, can be expanded, may be further merged with other sources of gas or liquids, and results in a fuel with different performance and properties. The fluid composite 1 has increased thermal efficiency, increased burning capacity, reduction of the specific charge of the fuel. Further, as part of the process of creation of the fluid composite 1 , gas is added and the volume and resulting speed of the fluid composite 1 is increased. The fluid composite 1 is a three-dimensional mixture made of a mixture of components in dynamic movement. The nature of the fluid composite 1 allows for an easier flow thought variable geometry designs cause by the compressible/expansive nature of the composite 1 . In another embodiment, water is added to the fluid composite to enhance hydrocarbon burning as known in the art. Further, the compressed gas will serve to propel the fluid composite 1 out of the nozzle head.
Once the fluid composite 1 is formed, the mass ratio of gas over liquid is fixed and does not change until the fluid composite 1 is finally expanded at a point of combustion, if it is expanded into an open volume with gas or liquid present; for example in a burning chamber of a burner or the piston of a diesel engine. Since the gas is compressible and the liquid is generally not compressible, as the pressure varies, the volumetric ratio unlike the mass ratio changes.
As for any composite 1 , such as diesel fluid composite, or any other composite, a compressibility limit exists. In an ordinary liquid, when a pressure change enters the medium, the liquid does not significantly change in volume. In an ordinary gas the medium is compressible and as the pressure changes in proportion with the pressure change (e.g. PV=NRT). For example, an increase by 100% of the pressure results in a decrease of half of the volume of the gas.
In the fluid composite, as the pressure changes, the liquid remains incompressible but the small spheres of gas 201 are compressible and will change in volume based on the evolution of volume of a sphere. For the above increase of the pressure by 100%, the volume of gas of a sphere V g =(4/3)πr g 3 must be halved so the pressure inside of a small gas bubble doubles. A sphere of gas 201 of diameter 50 μm and a radius of r g =25 μm (V g =65,500 μm 3 ) will increase in pressure twofold once the volume is halved (here to 32,750 μm 3 ). The new radius of the gas sphere 201 associated with this volume is r g =˜20 μm.
As the gas spheres grow smaller, understandably their capacity to shrink under pressure will reduce. The fluid composite 1 evolves when a large fraction of gas is present in the composite 1 from a gas like composite and morphs into and acts more like an incompressible liquid once the volumetric fraction of gas decreases. In the above example, if the composite is viewed in two dimensional, the gas proportion will evolve from an initial gas surface of S 1 =1964 μm 2 =πr 1 2 to a final gas surface of S 2 =1256 μm 2 =πr 1 2 . So the change in surface of the volume is S 2 /S 1 =1256/1964=0.64 or 64% for a decrease of the volume of the spheres of 50%. As the fluid composite 1 has a ratio of gas to liquid that closure to a liquid, this proportion changes accordingly. The fluid composite 1 has evolving unique properties based on partially and evolving compressible nature. Other properties such as latent heat, thermal capacity, specific heat, also evolve as a fluid composite 1 and not as two individual mixed elements. What is described and understood as the composite is a material, that includes a very large quantity of small volumes having different characteristics that result in creating an overall material called the composite 1 with characteristics and properties that different from a sum of its constituents.
FIG. 1 and associated FIG. 3 illustrate an incoming stream 101 of incompressible liquid made in one embodiment of hydro-carbons or a fuel. A hydraulic section of the device 102 is connected to an inlet such as a fuel pipeline or any other connector. As the stream 101 travels up the device illustrated here from left to right, it passes an entrance 103 and is split outwardly over a conical reflector 104 . At the base of the conical reflector 104 , the fuel reaches the opening channels 107 in the shape of a ring after traveling in the fixed external diameter cavity 106 where the fluid is accelerated. The stream 101 is split and enters the channels 107 and then reaches ring channel 109 to create a homogenous turbulent stream after a second step acceleration. Element 108 is an alignment element to help assemble and align the hydraulic and pneumatic parts.
The gas from an external source enters at channels 122 and travels up 121 until it expands at 120 around a conical shaped section. Another inner cone 119 serves as a guide element to direct the gas past the zone 117 and because of a reduction in section around the code to accelerate the gas into another ringed area with channels 116 . After the gas is flipped at the tip of the channels 116 , it then moves down opened channels 115 to meet the turbulent fluid. The fluid and the gas pass on opposite sides of the double coaxial reflector 111 before entering and mixing into the ring channel 112 and ultimately the ring 113 where merger and formation of the fluid composite 1 occurs. Line 114 illustrates the border at which the fluid composite 1 is formed and ultimately travels down the channels 123 for the accumulation of the fluid composite down in the apertures 124 into a single stream at the axial aperture 125 . A casing 127 is used for example as a heat sink or is used to help with post processing and alteration of a characteristic of the fluid composite 1 after it is formed. Greater details are given of this device and apparatus in the parent application hereby fully incorporated by reference.
FIG. 3 describes shows as 3 A and 3 B two sections, the first where a gas enters the device 100 and where the fluid composite 1 where the fluid composite 1 evolves. At FIG. 3A air or compressed gas enters at 301 at apertures for fastening pipelines where air arrives from a compressor. The gas evolves up channels 122 and reach the center 121 where the air then proceeds upwards to the area for the production of the fluid composite 1 . FIG. 3A further illustrates four channels 123 where the fluid composite 1 travels back to the area illustrated by FIG. 3B . In FIG. 3B the fluid composite 1 after traveling down from the main portion of the device past the area shown at 3 A merges back via channels 124 to the axial aperture 125 . Both FIGS. 3A and 3B show a X shape system with four apertures or four channels for the transfer of the gas and the fluid composite 1 respectively, but one of ordinary skill in the art will recognize that while one possible configuration is shown, any geometry, number of apertures, or number of channels is contemplated.
FIG. 4 is a cross-section of the device for producing a fluid composite of FIG. 3 including a post production chamber is used to further alter the fluid composite according to another embodiment of the present disclosure. At the back end (right side on the figure), an area is reserved 401 for post processing of the fluid composite 1 before it is released. For example, the device can include a coil or a cooling element to alter the temperature of the fluid composite 1 .
FIG. 5 is a cross-section of the device for producing a fluid composite of FIG. 1 including an acceleration nozzle 501 for entry of a secondary fluid such as air or water to be merged with the fluid composite 1 at 503 after it is released via the channel 502 . The passageway 503 can be a flat vortex creator with inclined passageway or be on a conical shape section 703 as shown at FIG. 7 . FIG. 6 is a cross-section of the device shown at FIG. 5 further including a secondary fluid inlet according to an embodiment of the present disclosure. Fluid pressurized or not is added such as additional combustion air to help push or accelerate the fluid composite 1 or simply to further increase the quantity of air in the mixture. The spiral 701 with tangential channels 704 is shown and is designed to create a vortex movement in the fluid composite 1 before it enters the outlet. FIG. 7 further includes an additional fluid inlet 705 for the entry of a fluid but this time directly in the area of the device 100 where the fluid composite 1 is created. FIG. 6 shows how a fluid inlet 602 includes an opening 603 for the passage of liquid into the area of interest 604 . In the illustrated embodiment, a groove 601 can be made to help guide the incoming liquid to the area of interest 604 .
What is described is a fluid activation device 100 to generate a aerated fluid composite 1 with a hydrodynamic portion in contact with the fuel 101 for activating at least a fuel by subsequently pressurizing the fuel 101 over for example a cone 104 and depressurizing the fuel 101 into a low pressure zone 113 for mixing of the liquid such as the fuel with a compressed gas entered via 122 to form a fluid composite 1 a shown on FIG. 2 . The device 100 further includes an aerodynamic portion shown as elements 118 , 119 , and 127 overlapping with the hydrodynamic portion at an interface region with conical shaped reflectors 111 for mixing a compressed gas from an external source 122 such as a compressor into the at least an input compressed fuel 101 at the low pressure zone of mixing 113 by subsequently pressurizing the gas, and changing a flow direction of the gas into the fluid composite 1 .
Further, the device 100 includes a secondary gas inlet 501 as shown at FIG. 5 to introduce gas or a different fluid into the fluid composite 1 to form an aerated fluid composite shown by the arrow on the right side of the device 100 . In one embodiment, the hydrodynamic portion includes a housing 105 with a cavity having a center cone 104 for pressuring the liquid 101 and directing the liquid 101 to a plurality of channels 107 and ultimately to capillary ring channel 110 between two conical shaped surfaces 111 for depressurization into the low pressure zone 113 .
In yet another embodiment, the secondary gas inlet 122 or as shown by a cross 301 on FIG. 3A is in a housing 127 of the aerodynamic portion 118 , 119 , and 127 . In another embodiment, the aerated fluid composite 540 as shown on FIG. 5 is a fluid composite 1 with more than a stoichiometric volume of gas in weight or a regulated stoichiometric volume for further compression of the fluid composite 1 . In FIG. 3A , the gas inlet 310 is radial to the housing, in another embodiment the housing further includes an external device for altering a characteristic of the aerated fluid composite 401 as shown on FIG. 1 .
In addition to providing information about the fluid composite 1 , and a device 100 for the production of the fluid composite 1 , what is also contemplated is a system 1000 where the device 100 for producing the fluid composite 1 is connected functionally. FIGS. 8 to 11 illustrate respectively each of the devices shown at FIGS. 1 , 5 , and 6 respectively as part of an integrated functional system 1000 with a device 100 where the fluid composite is used.
The system 1000 as shown includes the device 100 for the production of a fluid composite 1 . The system includes a compressor 806 with a pump and a nanometer 807 for the calibration and control of the flow of gas from the compressor 806 to the entry port 122 of the device 100 . The second input is a fluid pumped up from a tank 801 having a gauge or a level 802 and is pumped via the pump 803 through a meter 804 or filters/gauge 805 . In one embodiment, the tank 801 is filled with hydrocarbons or fuel. As drawn on FIG. 8 , an additional tank 811 is used to collect surpluses of fluid composite that is settled down in an depressurized state through a gauge or safety valve 810 and is recycled into the tank 801 . Finally, the fluid composite 1 produced by the device 100 is sent to a use, such as in one example an atomizer 8 for a combustion chamber 809 . While one use and one configuration of the system 1000 is shown, what is contemplated is the use of the device 100 as part of any system, with any technology, that requires the fluid composite 1 .
FIG. 9 shows the same structure as in FIG. 8 with the added description of the different zones for the creation of the fluid composite 1 . These zones are described as zones 901 to 909 . As described above, gas enters from the compressor 806 from one end while fluid enters from the tank 801 from the opposite end of the device 100 . The steps 901 to 909 are listed in this succession as the fluid passes from 901 to 905 , merges with the gas coming from the compressor 806 in zone 906 and finally moves out as shown in zones 907 to 909 . Zone 901 is a state the fluid passes from a continuous cylindrical flow to a ring shaped flow. Based on the angle of the different cones in this region and the associated effective surfaces open to the flow of fluid, the speed of the fluid is increased, slowed, or unchanged. In the configuration as shown, the speed of the fluid is accelerated in zone 901 and enters zone 902 the ring shape is formed so it aligns with the channels in zone 903 . Small streams of uniform cross section, such as cylindrical diameters of 5 to 50 micrometers are made. These channels have a fixed length so as to create a pressure drop in the fluid.
At zone 904 , a buffer zone allows for the collection of a small quantity of fluid before it may continue down to zone 905 and is dispersed. Zone 905 is a conic ring dispenser where the distance can be up to 200 micrometers but in one embodiment, the distance is 5 to 50 microns. As the streams move in this zone, the streams split in zone 903 take on a unique dynamic and kinetic configuration. Expansion based on the Bernoulli principle further increases the dynamic configuration of the stream of liquid. At zone 906 , the volume of the ring is such that pressure drops below a certain pressure so conditions of expansion and partial vaporization occurs. As observed, the flow downstream from zone 906 is of such a size as to allow for the ring at zone 906 to be in depression (i.e. where the flow is unclogged). At this border shown by 114 the fluid mixes in with the gas and the fluid composite 1 is formed in a partially compressible medium.
Zone 907 is a zone of intensive formation of cells of the fluid composite and a zone of high energy before the stream can stabilize in zone 908 as an accumulation of cells with a fixed pressure. Finally, at zone 909 , this area includes in one embodiment a vortex creator capable of creating a spiral movement within the fluid composite 1 by using some internally stored energy in the composite 1 .
FIG. 10 shows the configuration of FIG. 8 where the system further includes a second source of compressed air connected to the compressor 806 via a nanometer 1001 and a gauge for the determination and calibration of the flow and charge of compressed air for calibration. The system further includes as shown a second gauge 1003 for the primary flow of air. Finally, FIG. 11 includes other elements of one possible embodiment of the system 1000 such as a connector 1104 for entering a second source of fluid at zone 905 using a reservoir 1101 , a gage 1102 , and a load charge gauge 1103 . Other elements such as control elements 1005 and 1006 can be added to the use element 808 to better utilize the fluid composite 1 as a compressed media.
What is further described is a system 1000 for producing an aerated fluid composite with a source of fuel from the tank 801 connected to a hydrodynamic portion for activating at least a fuel in at least one of zones 901 by subsequently pressurizing the fuel 902 and depressurizing the fuel 903 into a low pressure zone for mixing 906 of the liquid with a compressed gas from the compressor 806 to form a fluid composite 1 . The source of compressed gas 806 is then connected to an aerodynamic portion as shown on FIG. 9 overlapping with the hydrodynamic portion at an interface region shown at 905 for mixing a compressed gas into the at least an input compressed fuel at the low pressure zone 906 of mixing by subsequently pressurizing the gas, and changing a flow direction of the gas at zone 905 into the fluid composite 1 created at 907 . The system 1000 also includes a secondary gas inlet 501 to introduce gas also from a compressor 806 or any other source into the fluid composite 1 and connected to the source of compressed gas to form an aerated fluid composite. In another embodiment, an aerated fluid composite outlet 766 is connected to an element 808 for use of the aerated fluid composite. The aerodynamic portion and the secondary gas inlet may also be connected to two different sources of compressed gas (not shown).
While in at least some examples described above, the fuel activation device is described generally as mixing fuel and water, the fuel activation device can mix various types of liquid components. For example, the fuel activation device can mix two dissimilar liquid components such as fuel and water. In some additional examples, the fuel activation device can mix two homogeneous components, such as gasoline and ethanol. In yet additional examples, the fuel activation device can mix at least three diverse components, such as gasoline, ethanol and water. In such embodiments, two of the components are provided to one of the liquid inputs to the hydrodynamic portion of the fuel activation device.
As shown in FIG. 13D , as the fuel-air mix stabilizes, the bubbles of fuel align to form a foam. While one regular quadratic cell configuration is shown, any configuration of optimized contact area based on the geometry of the cell is contemplated. In the stabilized fuel air mix, the average diameter of the fuel spheres (e.g., the diameter of the compressed gas core if present and the shell of fuel) becomes similar since the boundary conditions are the same across the entire fluid composite. While the average diameter of the fuel spheres is constant, the diameter of the kernel of compressed gas can vary between fuel spheres based on the local pressure of the fluid. For example, some fuel spheres, such as fuel sphere, have a core of a small or minimal diameter while other fuel spheres, such as fuel sphere, have a kernel that is so large that the coating on the fuel sphere has an insufficient thickness to provide stability due to forces of superficial tension. Smaller pressure allows for the gas kernel to expand creating a bubble with a smaller shell. Over time, fuel spheres such as fuel sphere are likely to burst. In some thermodynamic arrangements, in order to reduce the number of fuel spheres that burst prior to combustion, the time between formation of the foamed fuel and combustion of the fuel can be short.
In general, it can be desirable to form micro-bubbles having a ratio of the radius of the kernel of compressed to the thickness of the shell of liquid of between about 0.8 and 2.5 (e.g., between about 1 and about 2, between about 1.5 and about 2, about 2). Such a ratio again based on boundary conditions can provide a stable micro-bubble that is less likely to burst while still providing an increased surface area of the fuel. The foamed fuel (e.g., such as the fuel shown in FIG. 13D ) is inserted into a combustion chamber. When injected into the combustion chamber during a running cycle, the kinetic parameters of the activated volume of the fuel mix, in combination with the large active surface area of an activated unit dose of fuel, makes the burning process highly efficient.
Test Results
Different flows of liquid diesel fuel were entered into the device as shown on FIG. 1 at 101 . A rate of 7.5 gallons/hour, 4.5 gallons/hour and a rate of 2 gallons/hour, with an added weight ratio of 10% of the needed stoichiometric air used for burning to form composite fuel. The combustion performance was increased in the range of 25 to 45% in equal condition without the added air in the form of fuel. A reduction in toxic exhaust gasses has been observed. One parameter was adjusted, such as the pressure of the compressed air to regulate the nature and composition of the fuel composite 1 . Upon expansion of the composite fuel, this mixture remain a composite.
Instead of 7.5 gallons of fuel producing 100 MJ of energy in one hour, the fuel composite made of 5.25 gallons of fuel and 89.25 gallons of air at a pressure of 17 bars will produce the same energy output, thus saving 2.25 gallons of fuel well within the range of 25 to 45%. Testing conditions were within 23% of calculated values and corresponds in a commercial boiler to an increase of fuel performance from a value of 75% to approximately 87%.
One term that may be used to described the liquid fluid composite 1 is an emulsion or micro-emulsion of liquid where the mixture inside the different droplets is of a geometry based on the different size of the structure of the device for the production of the emulsion. For example, the different channel are of a diameter to produce the emulsion or the fuel composite of determined size without the need of surfactants or other chemicals made to change the property of the fuel. In one embodiment, the flow rate of the different liquids/gas entering the device are varied to alter the pressure, geometry, and different dynamic proportions of the emulsion. The term fluid composite 1 as part of this disclosure must be construed to be, for example a highly structure mixture, with either microscopic structured mix or macroscopic structured mix as described and shown. Emulsions or what is generally described as highly structured mixtures or more generally composites can be used in many different fields of technology including for combustion chambers, in the food industry, in the pharmaceutical industry, or for general mixing of fluids, liquids, liquids and gas, or fuel and gas.
It is understood that the preceding is merely a detailed description of some examples and embodiments of the present invention and that numerous changes to the disclosed embodiments can be made in accordance with the disclosure made herein without departing from the spirit or scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention but to provide sufficient disclosure to one of ordinary skill in the art to practice the invention without undue burden. | 4y
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FIELD OF THE INVENTION
This invention relates generally to a construction technique of joining a rotatable right circular cylinder and shaft and, more particularly, to a method of making such junction free of transmitted distorting strain in the cylinder.
BACKGROUND OF THE INVENTION
In the construction of precision machine components, such as a right circular cylinder and shaft rotating at high speed in a gyroscope, a hydraulic actuator or bearing in a magnetic disc memory, the dimensions of the diameter, length, cylindricity and squareness all become critical Careful machining, lapping and measuring are necessary to achieve the demanded accuracy that is typically within a few microinches.
The processes do not readily lend themselves to inexpensive mass production of such components because of the repetitive dimensional checking and finishing, such as lapping and honing, that can be required. This is especially true with elements that rotate on gas films and must avoid interference with mating parts. Such elements operate with little clearance and need to be held to close tolerances to achieve the stability and reliability necessary.
Precision and fabrication efficiency, which can be achieved with existing production equipment, can also be limited by the design of the components. Although redesign can often aid the manufacturing processes, changes in either a component configuration or its processing may bring about other problems.
OBJECTS AND SUMMARY OF THE INVENTION
It is accordingly a primary object of this invention to provide a method of constructing an assembly of a bored right circular cylinder with input or output shaft which enables the two cylinder ends to be finished concurrently to provide parallel surfaces perpendicular to the cylinder axis and later joining the cylinder and shaft in a low stress joint.
Another important object of this invention is to provide a method of joining a right circular cylinder having a center bore with a shaft in which the shaft cannot transmit stresses sufficient to strain or distort the cylinder during subsequent environmental changes.
Yet another object of this invention is to provide a method of constructing a bored right circular cylinder to be precisely made on conventional grinding, lapping and honing equipment and later assembled with the shaft while retaining the original cylinder precision as to cylindricity, end face parallelism, squareness and flatness.
A still further object of this invention is to provide a right circular cylinder and shaft assembly having narrower dimensional tolerances and improved dimensional stability through varying temperatures.
It is also a significant object of this invention to provide a right circular cylinder suitable for use in a high speed gas bearing and joined with an, input or output shaft in such a manner that the shaft(can sever its bond with the cylinder in the event of bearing seizure and remain an integral link between devices attached at the opposite shaft ends.
The foregoing objects are attained in accordance with the invention by separately fabricating a bored right circular metal cylinder with known precision equipment that can machine, lap or hone the cylinder and its ends to a high degree of accuracy as to cylindricity, end face parallelism, end squareness and flatness relative to the cylindrical surface without the presence of a shaft, thus permitting concurrent finishing of the entire cylinder ends to dimensional tolerance of a few microinches. The shaft for assembly with the cylinder bore is separately machined to less accuracy and made of hollow stock that is slotted or formed within the bore area to weaken the shaft sufficiently to prevent transmission of any shaft strain to the cylinder that may produce cylinder distortion. The shaft is attached to the cylinder only at limited surface areas that are adhesively attached to the bore wall for accomplishing assembly.
This method of fabrication and the resulting assembly enable construction of a cylinder having highly accurate dimensions that is especially suitable for rotation at high speed in a gas bearing demanding extremely narrow clearances. With known fabrication methods the cylinder shaft is integral with the cylinder and interferes with end face lapping and honing procedures, making the components labor intensive and costly. The invention, by using a separate shaft, permits the cylinder end faces to be lapped and honed with better precision and alignment, and easier for mass production of such components.
With the known assembly of cylinder and shaft as two components, stress in one can effect distortion in the other. Since the cylinder usually requires the greatest precision and tolerance, the shaft of this invention has been weakened by using a hollow element that is made further pliant by wall formation that may consist of removal of wall material or special wall configurations at the zone of attachment. Bosses or projections are used as the exterior attachment surfaces of the shaft for adhesively joining cylinder and shaft.
The foregoing and other objects, features and advantages will become apparent from the following more particular description of a preferred embodiment of the invention with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a sectional elevation view of a right circular cylinder and shaft constructed in accordance with the principles of this invention;
FIG. 2 is a sectional end view taken along the line 2--2 in FIG. 1;
FIG. 3 is an alternative embodiment of the method of joining a right circular cylinder and shaft as an assembly in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, there is shown an assembly of a right circular cylinder 10 having end faces 1 and a hollow shaft 12. Shaft 12 is formed with annular collars 13 that are segmented by longitudinal slots 14 at ninety degree intervals about the shaft. The shaft is joined to the cylinder within its central bore 15 at lands 16 by adhesive.
Such an assembly is typically of metal, such as steel, and may be used in a gyroscope, magnetic drum memory rotor, bearing or the like. The cylinder is enclosed by a journal or sleeve (not shown) for relative rotation at extremely high speeds. Usually the right circular cylinder and its journal are separated from each other by a thin gas film such as air, that is either a self-acting film or one produced by pressurized jacking fluid. With an accurately machined assembly and journal, rotation is accomplished with little friction and a high degree of stability, due t the film stiffness. Achievement of the necessary dimensional accuracy within a few millionths of an inch for the cylindricity, end face perpendicularity, end face parallelism, squareness and flatness requires hours of machine finishing and measuring, thus making the final product unreasonably costly.
It has been discovered that a significant portion of the manufacturing time can be eliminated and the finishing equipment used to better efficiency by fabricating right circular cylinder 10 as a separate component without an integral shaft. When the cylinder is machined alone, its two end faces 11 can be lapped and honed simultaneously and in large groups in a flat lapping machine during a single setup thereby attaining improved control and accuracy. Absence of shaft 12 permits the lapping plates to advance entirely across the end faces without encountering a limiting projection. This procedure also enables fabricating the end faces with improved parallelism and perpendicularity relative to the exterior curved surface of the cylinder and results in improved end face flatness, all critically necessary for a gas or fluid bearing support system.
Shaft 12, which may be either an input or output shaft, is formed as a separate element from a machined rod and is preferably hollow. However, the addition of a conventional separate shaft to bore 15 of cylinder 10 by known techniques such as a press fit, brazing or adhesive, transmits stresses to cylinder 10, producing unacceptable distortive strain sufficient to exceed the required manufacturing tolerances. Had the shaft been an integral portion of the cylinder, internal stresses would have been relieved via heat treatment. It has been found that cylinder 10 and shaft 12 can be formed separately and joined adhesively or by brazing at low temperatures at connections having limited contact area such that lower stresses from the shaft due to temperature changes are insufficient to produce strain in the cylinder.
In the preferred embodiment, hollow shaft 12 is formed from stock that is drilled or bored leaving sufficient wall thickness for the anticipated loading. The tube is machined and ground on its outer surface to provide a plurality of annular collars 13 that fit within central bore 15 of cylinder 10. In this embodiment, two are shown. The shaft wall is then machined to provide slots 14 that segment collars 13 and the shaft wall at ninety degree intervals. The longitudinal axis of each slot parallels the longitudinal axis of the shaft. An adhesive, preferably of the anerobic type, (curable in the absence of air) is applied to the outer surfaces of the collar segments, the cylinder and shaft joined, and the adhesive cured. This adhesive, however, will break loose if bearing seizure were to occur and cylinder 10 were suddenly stopped from rotating. A weakened shaft side wall, due to piercing slots 14 and the small junction areas between the segments of collars 13 and surface of bore 15, limits any forces transmitted radially to cylinder 10 by the shaft due to its different coefficient of expansion or other external force applied to the shaft.
Contact segment area is preferably kept at the minimum necessary to start, stop or carry the loading on the shaft and cylinder. The size of the collar segments and area of remaining shaft wall depend upon the cylinder and shaft application and torque required. It is desirable that the shaft be unable to transmit or produce strain in cylinder 10 due to differential coefficients of expansion between the two members 10 and 12. Slots 14 are located and are of size and extent such that there is discontinuity of contact area in any transverse section across the assembled members. By providing the discontinuity, the shaft is unable to transmit significant stresses to the cylinder when the former has the greater coefficient of expansion. Slots 14 may be placed at other locations and parallel or at acute angles relative to the longitudinal axis of the shaft. The number or position of slots 14 need not be prescribed but are more correctly determined by the loading and manufacturing methods employed.
An alternative attachment technique between a shaft and cylinder is illustrated in FIG. 3 where the shaft wall 20 is formed in accordion or pleated fashion to produce a plurality of attachment points at external peaks 21. Attachment to the surface of bore 15 is preferably with an adhesive. The pleating provides discontinuous circumferential attachment areas and the surface convolutions of the shaft enable expansion of the shaft wall without transmitting contorting stress to cylinder 10.
In the foregoing embodiments, a highly accurate right circular cylinder can be fitted with a separate input or output shaft without concern that the union will produce distorting strain in the cylinder. This enables the cylinder to be manufactured with ultimate precision and used reliably in gas bearings. Further, because the end faces of the cylinder can be finished in a flat lapping machine across their entire surfaces with better accuracy the improved finish renders the cylinder highly suitable for thrust bearing applications. In the event, cylinder 10 is used in a gas bearing and seizure occurs, shaft 12 can break free of the cylinder, yet retain any elements secured to its ends.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to dispensing apparatus, and more particularly pertains to a new and improved golf ball dispensing apparatus wherein the same is arranged for dispensing packages or individual golf balls from containers.
2. Description of the Prior Art
In the display and sale of golf balls, individuals are encouraged to buy packages of a plurality of golf balls. Individuals not desiring to purchase or obtain such pluralities of golf balls in components are discouraged. The invention sets forth an organization to accommodate both complete packages and individual golf balls from the associated packages. Examples of prior art dispensing apparatus set forth in the prior art is exemplified in U.S. Pat. No. 3,869,137 to Byrom wherein a portable storage cart includes a column of removable ball members therefrom.
U.S. Pat. No. 4,917,282 to Hufford wherein a ball holder is formed of a resilient material, with apertures therewithin to resiliently secure various golf balls positioned therewithin.
As such, it may be appreciated that there continues to be a need for a new and improved golf ball dispenser apparatus as set forth by the instant invention which addresses both the problems of ease of use as well as effectiveness in construction and in this respect, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of dispensing apparatus now present in the prior art, the present invention provides a golf ball dispenser apparatus wherein the same is arranged for dispensing packages or individual golf ball members. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved golf ball dispenser apparatus which has all the advantages of the prior art dispensing apparatus and none of the disadvantages.
To attain this, the present invention provides a golf ball dispenser apparatus arranged for accommodating plural columns of packages permitting ease of dispensing of the packages with separation of the packages and permitting removal of individual components therefrom.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
It is another object of the present invention to provide a new and improved golf ball dispenser apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved golf ball dispenser apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved golf ball dispenser apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such golf ball dispenser apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved golf ball dispenser apparatus which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of the instant invention.
FIG. 2 is an orthographic side view of the instant invention.
FIG. 3 is an orthographic frontal view, taken in elevation, of the instant invention.
FIG. 3a is an isometric illustration of the invention mounting a severing tool thereon.
FIG. 4 is an isometric illustration, somewhat enlarged, of the severing tool utilized by the instant invention.
FIG. 5 is an isometric illustration of the apparatus utilizing golf magazine tubes.
FIG. 6 is an enlarged isometric illustration of a magazine tube utilized by the instant invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 6 thereof, a new and improved golf ball dispenser apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, the golf ball dispenser apparatus 10 of the instant invention essentially comprises a housing including a rear wall 11, with a bottom wall 12 integrally and orthogonally mounted to a lower edge of the rear wall 11 extending coextensively thereof. The rear and bottom walls are each defined by a predetermined first length, with the rear wall defined by a first height. Respective right and left side walls 13 and 14 are orthogonally mounted to the rear wall 11 and bottom wall 12 and defined by a first height substantially equal to the first height defined by the side walls 13 and 14. A series of equally spaced partition walls 15 are fixedly and orthogonally mounted relative to the rear wall 11 extending from an upper terminal edge of the rear wall to a position spaced above a lower terminal edge of the rear wall. Partition walls 15 are accordingly arranged in a parallel relationship relative to one another and are defined by a second height less than the first height to space each partition wall above the bottom wall 12. Each partition wall 15 includes an abutment wall 16 orthogonally mounted and coextensive with each partition wall equal to a height defined by the second height, and accordingly are arranged parallel relative to the rear wall 11. Abutment end walls 17 are provided and mounted to a forward side edge of each side wall spaced from the rear wall 11, wherein the abutment walls 16 mounted to each side wall are of a width substantially equal to one-half a width of each partition wall and defined by a second height. In this manner, a gap 18 is defined between the coplanar partition walls and abutment walls providing access to a compartment 19 of a generally rectangular parallelepiped configuration to accommodate a plurality of packages "p", of a type as illustrated in FIGS. 3a and 4. The packages "p" are stacked in columns within each of the compartments 19, wherein a lowermost package "p" is removed and each column thusly formed
As the packages "p" normally contain a plurality of components such as golf balls therewithin and are typically formed with a polymeric type covering, a severing tool 20 is arranged in a modified construction of the invention mounted to a forward face of one of said abutment walls 16. Typically, the abutment walls 16 are arranged for receiving the severing tool 20 but if desired, an abutment end wall 17 may also accommodate the tool 20. The tool 20 includes a lower block 21 spaced from and positioned below an upper block 23 in a parallel relationship. The lower block 21 includes a lower bore 22, with the upper block 23 including an upper bore 24 that are coaxially aligned with a piercer rod 25 reciprocatably mounted between the lower and upper bores 22 and 24 to include a severing pointed lower end 27 projecting above the lower block, while a piercer rod head 26 projects above the upper block to enhance manual engagement and projection of the piercer rod from a first position spaced above the lower block to a second position below the lower block, as illustrated in FIG. 4. A spring member 28 is captured between the upper and lower blocks and is arranged to normally bias the piercer rod 26 into the upper raised position. A retainer plate 25a is fixedly mounted to the rod 25 to provide an operative retainer plate upon which the spring member 28 cooperates to effect upward biasing of the rod 25.
Subsequent to severing of the package "p", a removal of a single or plurality of balls therefrom and having golf balls remaining, such golf balls may be positioned within "J" shaped magazine tubes 29 secured to each forward face of an associated abutment wall 16. The "J" shaped tubes 29 include a primary tube 30 projecting into an upwardly curved lower tube that includes a tube outlet opening 31. The lower tube includes a plurality of diametrically aligned recesses 32 directed across a lower terminal end of the outlet tube 31 that is positioned below the upper entrance end of the primary tube 30. The tube entrance end 33 receives a column of the golf balls "G" therewithin, wherein the slots 32 permit ease of manual access to the golf balls for their individual removal from the "J" shaped magazine tube 29, as illustrated.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | 4y
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BACKGROUND OF THE INVENTION
The invention relates to lightweight and very strong copper-clad aluminum composite wire (hereinafter referred to as "Cu/Al composite wire") and a method of manufacturing such Cu/Al composite wire, which is used for internal conductors for coaxial cables, electromagnetic shield braided wire for coaxial cables, electric wiring cables for airplanes, automobiles, electric automobiles, portable VTRs and TV sets, voice coards for speakers, magnet wire, and the like.
FIG. 1 is a sectional view of a Cu/Al composite wire. Reference numeral 1 designates an aluminum core; and 2, a copper cladding layer around the aluminum core 1.
Having such a makeup, the copper cladding layer in the conventional Cu/Al composite wire generally forms from 5 to 20% of the cross-sectional area of the composite wire. The aluminum core material is a high-purity aluminum alloy whose purity is 99.9% or more or an Al-Fe alloy containing 0.9 to 2.5 percent iron (see Japanese Patent Unexamined Publication No. 53-110082). Such Cu/Al composite wire had a conductivity of 60 to 70% IACS (International Annealed Copper Standard), a specific gravity of 3.0 to 3.95, a tensile strength of 10 to 20 kgf/mm 2 (soft-drawn) and 20 to 35 kgf/mm 2 (hard-drawn) (American Society for Testing Materials (ASTM) B566-88).
As described above, the coverage of the copper cladding layer is from 5 to 20% at the cross-sectional area. Often the copper cladding layer breaks to expose the aluminum core when the composite wire is soldered to printed circuits or boards, thus causing defective connections. Also, adjusting, stranding, and handling of the wire in thin diameter during the intermediate process may cause damage to the copper cladding layer, leading to exposure of the aluminum core, which the becomes corroded or breaks, etc.
On the other hand, if the copper clad takes up more than 20% of the total cross-sectional area of the wire, the strength of the core against the copper clad layer is impaired in the case where the core material is a high-purity aluminum alloy material. In this case, the aluminum core may break easily when the wire is drawn. Consequently, drawing of wire to obtain small sizes is difficult. Also, when high-purity aluminum alloy is used, even if the copper forms less than 20% of the cross-sectional area of the wire, the tensile strength is small (35 kgf/mm 2 or less). Such a wire exhibits insufficient strength which is fatal as a wiring conductor when drawn to be 0.15 mmφ or less in diameter. In addition, the conventional Cu/Al composite wire has exhibited conspicuous inferiority in corrosion resistance to salt water at the end faces thereof compared with ordinary copper wire. Further, although various types of copper-cladding materials are used while utilizing the electromagnetic shielding property of copper, no study has been made on the Cu/Al composite wire.
SUMMARY OF THE INVENTION
The invention has been made in view of the above circumstances. Accordingly, an object of the invention is to provide copper-clad aluminum composite wire and a method of manufacturing such wire.
To achieve the above object, according to a first aspect of the invention, a copper-clad aluminum composite wire has a core that is made of an Al-Mg alloy and circumferentially clad with copper. The aluminum alloy is composed of 1.5 to 10.0 percent by weight of Mg, partial additives such as Cr and Mn, ordinary impurities, and aluminum, with the aluminum being in such a content as to form the rest of the alloy composition. The copper whose purity is 99.9% or more forms from 20 to 40% of the cross-sectional area of the wire.
According to a second aspect of the invention, a method of manufacturing a copper-clad aluminum composite wire comprises the steps of: when cold-cladding a core material with copper in the above-mentioned composition, drawing the copper at a percent reduction of 20% or more using a cladding die (see FIG. 6) whose half angle α is from 15° to 30° to obtain a cladding wire; drawing the cladding wire for elongation at a percent reduction of 70% or more using a drawing die whose half angle α is from 4° to 15° at least once; and subjecting the thus drawn wire to an annealing process.
The diameter of the aluminum alloy core is 6.0 mmφ or more. When the aluminum alloy core is formed into the cladding wire, the cladding die has a half angle α of from 15° to 30° and the length d of the bearing zone is D/6≦d≦D/4 (where D is the diameter of the die).
The annealing process is carried out at temperatures from 200° to 400° C. for from one minute to 24 hours. In the method, the drawn wire may be further subjected to a cold drawing process for elongation at a percent reduction of 50% or more at least once after the annealing process.
The copper-clad aluminum composite wire of the invention uses as an aluminum core 1 in FIG. 1 an Al-Mg alloy composed of 1.5 to 10.0 percent by weight of Mg, partial additives such as Cr and Mn, ordinary impurities, and aluminum, the aluminum being in such a content as to form the rest of the alloy composition. Such aluminum core 1 is cladding with copper whose purity is 99.9% or more so that the copper forms 20 to 40% of the cross-sectional area of the wire.
In general, the Al-Mg alloy of the present invention includes Zn of about 0.05 wt %, Cu of about 0.02 wt %, Cr of about 0.05 wt %, Mn of about 0.05 wt %, Fe of about 0.1-0.2 wt %, and Si of about 0.02 wt % other than Al and Mg.
The inventors have studied the aluminum core material of the Cu/Al composite wire and have obtained the following findings.
(1) If a high-purity aluminum alloy such as described above (JIS1000 Series or an aluminum alloy having a high purity of 99.9% or more) is used, strength of the core is so low compared with that of the copper cladding layer that and breakage originates frequently from the core during the drawing process when producing small-diameter wire. The produced wire has low bending resistance and low corrosion resistance to salt water.
(2) Even if an Al-Cu alloy (JIS2000 Series) is subjected first to an ordinary softening process in which the alloy is heated to 250° to 400° C. and cooled, and then a drawing process for elongation, strength of the core is so low as to be frequently broken during the drawing process to produce small-diameter wire. The bending resistance is also low. To improve the strength, the Al-Cu alloy is usually subjected to the T6 thermal treatment, in which the alloy is subjected to solution treatment and aging treatment. The temperature at which the solution treatment is carried out, is 400° C. or more, thus producing brittle intermetallic compounds at the boundary between Cu and Al. This becomes the cause of breakage of wire, making this alloy unsuitable as a core material. The corrosion resistance of the alloy to salt water is noticeably poor, making the alloy unsuitable.
(3) An Al-Mn alloy (JIS3000 Series) may have higher strength depending on how much Mg is added, but the strength does not make this alloy suitable enough. The addition of Mn disadvantageously increases the softening temperature; a Mn-added product (1.2% Mg) requires that the softening temperature be 400° C. or more, thereby similarly causing brittle intermetallic compounds to be produced at the boundary between Cu and Al. However, the corrosion resistance to salt water is fairly improved.
(4) An Al-Si alloy (JIS4000 Series), exhibiting poor drawability to small-diameter wire, is thus unsuitable as a core material. The corrosion resistance to salt water is also extremely unsatisfactory.
(5) An Al-Mg alloy (JIS5000 Series) has been found suitable as a core material of the Cu/Al composite wire of the invention. However, if the addition of Mg is less than 1.5 percent by weight, strength of the core is inadequate and becomes lower than that of the copper cladding layer, which may cause the wire to break easily. If Mg is added by 10 percent by weight or more, although the strength becomes high, ductility of the core material is decreased, exhibiting low drawability to 300 μm or less and thus making the alloy unsuitable as the core material. The addition of 1.5 to 10.0 percent by weight of Mg makes the alloy stronger than the circumferentially cladding copper layer, and the softening process can be carried out at the temperature from 200° to 400° C. in the course of elongation process, so that the drawability to 300 μm or less id improved to a remarkable degree.
(6) An Al-Mg-Si alloy (JIS6000 Series) is unsuitable for its poor strength obtained under ordinary heat treatment and drawing processes. A solution treatment at 450° C. or more improves the strength but, at the same time, brittle intermetallic compounds are similarly produced at the core boundary to the copper cladding layer, thus making the alloy unsuitable.
From the above findings, Al-Mg alloys having 1.5 to 10.0 percent by weight of Mg (containing the addition of Cr and Mn) are suitable as a material of the aluminum core, particularly, Al-Mg alloys having 4 to 6 percent by weight of Mg are optimum.
The ratio in cross-sectional area of Cu to Al of the Cu/Al composite wire will be discussed. If the copper cladding layer forms less than 20% of the total cross-sectional area of the wire, the copper cladding layer is broken to expose the aluminum core as described previously, causing wire breakage and defective connections. Since an Al-Mg alloy used as a core material in the Cu/Al composite wire of the invention has low conductivity, the makeup of the wire in which the copper cladding layer takes up less than 20% may lead to a case where conductivity of the Cu/Al composite wire is smaller than 40% IACS, making the wire unsuitable as a conductor. On the other hand, if the copper cladding layer forms more than 40% of the total cross-sectional area of the wire, the specific gravity becomes more than 5.2 thus reducing the lightweight advantage making the wire unsuitable. Therefore, by setting the ratio in cross-sectional area taken up by the copper cladding layer from 20% to 40%, the conductivity problem is eliminated, and the specific gravity can be confined to a value of less than 5.2, which contributes to the lightweight benefit of the wire.
Considering the electromagnetic shielding property, if the purity of copper used in the copper cladding layer is less than 99.9%, the conductivity of the wire is decreased together with the shielding property. Also, when the copper cladding layer forms less than 20%, particularly less than 10%, of the cross-sectional area, the shielding effect tends to decrease greatly, while the shielding effect remains unchanged when the copper cladding layer forms 40% or more.
Since purities of copper of the copper cladding layer less than 99.9% reduce conductivity of the Cu/Al composite wire, such copper is unsuitable.
Since composite clad wire such as that of the invention is used where a size of 100 μm or less is required, the cladding material and the core material are preferably bonded metallurgically to some extent. Any clearance between these materials makes drawing into thin wire difficult. It has been found that success in drawing owes much to three factors: the cladding method employed when a core material having a certain thickness is clad with a cladding material; to the subsequent drawing method for elongation; and to the annealing conditions. A core material, which is an aluminum alloy, in the invention preferably has a diameter of 6.0 mm or more for satisfactory metallurgical bonding. When the materials are passing through a cladding die whose half angle α is from 15° to 30° to prepare cladding wire, the cladding material is elongated to thereby generate slide resistance on the core material, i.e., an Al alloy, which increases the degree of contact. In contrast thereto, when the half angle α of the die is less than 15°, particularly, less than 10°, the slide resistance is so small that the cladding material is not brought into sufficient contact with the core material. If α exceeds 30°, particularly, 35° or more, the cladding material is drawn so excessively as to be easy to break. Consequently, it is preferable to set the half angle α of the die between 15° and 30°. Further, the use of the die whose half angle falls within the above range allows a predetermined ratio in cross-sectional area of the cladding material to be obtained. In addition, it is important to set the length d of the bearing zone of this die between D/6 and D/4 (D is the diameter of the die). When d is less than D/6, the surface pressure at the time that the cladding material is slid is insufficient, thus causing insufficient contact. If d is more than D/4, the die surface is subjected to excessive wear, thus not only deteriorating the life of the die but also causing breakage of the cladding material, tucking, and the like.
Still further, in drawing the obtained cladding wire for elongation, it is preferable that after the wire is drawn at a percent reduction of 70% or more using a drawing die whose half angle α is from 4° to 15°, the reduced wire is annealed at temperatures from 200° to 400° C. to improve the bonding property between the core material and the cladding material. Half angles being less than 4° cause the die to be worn greatly, while half angles in excess of 15° cause the cladding layer to be out of position, which is likely to result in tucking. Annealing temperatures below 200° C., particularly below 150° C., are not enough to induce mutual diffusion, while an annealing process at a temperature in excess of 400° C. for a long time produces brittle intermetallic compounds, which leads to easy breakage of wire. Thus, such wire cannot make a satisfactory hoop. Further, the annealing time is preferably from one minute to 24 hours. Annealing for less than one minute is not enough to obtain the effect of mutual diffusion, while annealing that is longer than 24 hours is too expensive and does not provide performance improvement that is commensurate with the expended cost.
After such annealing, the wire is cold-drawn to reduce the cross-sectional area by 50% or more at least once, so that the core material and the cladding material can be bonded with no clearance therebetween. The strength and bending resistance of the Cu/Al composite wire can thus be improved.
According to such a method, tensile strength of the Cu/Al composite wire is 30 kgf/mm 2 or more, and even as large as 60 kgf/mm 2 . Even if the core material is softened at temperatures from 200° to 400° C., the tensile strength is between 20 and 35 kgf/mm 2 .
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a horizontal sectional view of Cu/Al composite wire;
FIG. 2 is a diagram illustrative of an apparatus for manufacturing the Cu/Al wire;
FIG. 3 is a diagram illustrative of an apparatus for manufacturing the Cu/Al wire when a tubular claddingding material is used;
FIGS. 4(a) to 4(d) are diagrams illustrative of a bending test;
FIG. 5 is a horizontal sectional view of stranded Cu/Al wire;
FIG. 6 is a diagram illustrative of a die; and
FIG. 7 is a graph showing shield effects of the Cu/Al wire.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 is a diagram illustrative of an apparatus for manufacturing Cu/Al wire.
An aluminum core material 11 is paid off from a core material supply block 13 and straightened by a straightener 14. The straightened core material is cleaned by a surface cleaning unit 15 and introduced into a casting die 18. Simultaneously, a copper tape 12 paid off from a copper tape supply block 16 is similarly cleaned by a surface cleaning unit 17 and introduced into the casting die 18 so as to be laid along the core material 11. The thus laid copper tape 12 in the casting die 18 is cast to clad the core material 11 concentrically. The side ends of the copper tape 12 to be jointed is butt-welded by a TIG welder 20. The thus welded materials are then formed into a cladding wire d by a cladding die 21 and rewound by a rewinder 24. In the form of cladding wire the aluminum core material 11 and the copper tape 12 are in intimate mechanical contact with each other. In FIG. 2, reference numeral 19 designates a squeeze roller; 22, a shielded container for forming nonoxide atmosphere; and 23, a rewinding capstan.
FIG. 3 is a diagram illustrative of an apparatus for manufacturing Cu/Al composite wire when a tubular claddingding material is used.
Cu/Al composite wires in each of which the copper clad layer forms 30% of the cross-sectional area of the wire were obtained by cladding and drawing while using the apparatus for manufacturing Cu/Al composite wire shown in FIG. 2 under the following conditions. The core materials were the aluminum alloy wires made of: (a) pure aluminum (JIS1050); (b) Al-Cu alloy (JIS2011); (c) Al-Mn alloy (JIS3003); (d) Al-Si alloy (JIS4047); (e) Al-Mg-Si alloy (JIS6061); (f) Al-Mg alloy (JIS5056) and (g) Al-Mg alloy containing 0.9 percent by weight of Mg (JIS5005) ((f) and (g) were core materials of the invention). The diameter of each core wire was set to 8.5 mmφ. The cladding material was a copper tape of 1.0 mm thick and 55 mm wide made of oxygen free copper (99.99%). A cladding die whose diameter is 10.2 mmφ and whose half angle α is 30° was used to clad and draw the materials.
Further, (h) a Cu/Al composite wire in which the copper clad layer takes up 42% of the cross-sectional area of the wire was produced by cladding and drawing the core material Al-Mg alloy (JIS5056) and a cladding material copper tape of 1.4 mm thick and 55 mm wide made of oxygen free copper. In this case, a cladding die whose diameter was 11.2 mmφ and whose half angle α was 25° was used. Still further, a Cu/Al composite wire in which the copper cladding layer forms 16.5% of the cross-sectional area of the wire was obtained by cladding and drawing the core material (JIS5056) and a copper tape of 0.5 mm thick and 40 mm wide made of oxygen free copper. In this case, a cladding die whose diameter was 9.3 mmφ, whose half angle α was 25°, and whose bearing length was 1.9 mm was employed.
These Cu/Al composite wires were cold-drawn to reduce their diameter to 4.0 mmφ and then annealed at 300° C. for one hour. The annealed wires were cold-drawn again so that their diameter was reduced to 1.0 mmφ and annealed again at 300° C. for one hour. The thus heat-treated wires were subjected to cold drawing to reduce the diameter to as thin as 0.15 mmφ.
While the Cu/Al composite wires using the Al-Cu alloy and the Al-Mg-Si alloy as the core materials were subjected to a solution treatment at 520° C. as an additional heat treatment to improve the strength of the 1.0 mmφ semi-finished wires, brittle Cu-Al intermetallic compounds were produced at the boundary and this caused breakage of the wires. Consequently, the treatment was suspended at this point.
The Cu/Al composite wires whose diameter reached 0.15 mmφ without breakage were subjected to mechanical property tests such as a tensile strength test (kgf/mm 2 ), a bending resistance test shown in FIGS. 4(a)-4(b) as well as a soldering test. Further, a salt spray test was conducted on these wires in the atmosphere using 5% salt water (pH=6.5 to 7.2) at 35°±1° C. in spraying amounts of from 0.5 to 3.0 cc/hour.
FIGS. 4(a) to 4(d) are diagrams illustrative of the bending test. An end of a sample piece of Cu/Al composite wire 32 is clamped between a pair of steel blocks 31, each having a roundness value of corner (R) of 0.5 mm, and a weight 33 weighing 50 g is suspended on the other end (FIG. 4(a)). Then, the steel blocks 31 were tilted 90° toward the right as shown in FIG. 4(b) to bend the composite wire 32. This operation was counted as one bending. The steel blocks 31 were returned in the original position as shown in FIG. 4(c) and were then tilted toward the left to give a second bending to the composite wire 32 as shown in FIG. 4(d). By repeating this operation, the number of bendings was counted until the wire was broken.
The core material composition, processed states, and mechanical properties of the above-mentioned Cu/Al composite wires are shown in Table 1. For reference, comparative examples of a single strand of titanium wire, a single strand of duralumin wire, and a single strand of tough-pitch wire, whose diameter is 0.15 mmφ, are also presented.
TABLE 1__________________________________________________________________________Type of core material and major element added(Wt %)JIS Cu coverage ConductivityNo. No. Cu Si Mn Mg Cr Al (%) Specific gravity IACS__________________________________________________________________________ %1 1050 ≦ ≦ ≦ ≦ -- ≧ 30 4.5 71 0.05 0.25 0.05 0.05 99.52 2011 5.5 0.2 -- -- -- Remaining " 4.7 58 content3 2011 5.5 0.2 -- -- -- Remaining " 4.7 58 content4 3003 1.1 0.2 1.2 -- -- Remaining " " 65 content5 4047 0.1 12 0.1 0.05 -- Remaining " " 55 content6 6061 0.3 0.6 0.1 1.0 0.2 Remaining " " 61 content7 6061 0.3 0.6 0.1 1.0 0.2 Remaining " " 61 content(8) 5056 0.05 0.1 0.1 5.2 0.10 Remaining 30 4.5 52 content(9) 5052 0.10 0.25 0.1 2.5 0.20 Remaining 25 4.3 52 content10 5056 0.05 0.1 0.1 5.2 0.10 Remaining 16.5 3.7 39 content11 5005 0.08 0.2 0.1 0.8 -- Remaining 30 4.5 66 content12 5056 0.05 0.1 0.1 5.2 0.10 Remaining 42 5.3 59 content13 Single-strand titanium wire 4.5 2.214 Single-strand duralumin wire (JIS 2011) 2.8 4015 Single-strand tough-pitch copper wire 8.9 100__________________________________________________________________________ Tensile Bending test strength at (50 g, 0.5 mmR, 0.15 mmφ right-angle solder- 500-hour salt spray testNo. Drawability up to 0.15 mmφ (kgf/mm.sup.2) bending) ability End face Surface__________________________________________________________________________1 Δ Frequently broken 22 35 ◯ Al core was No corroded by 8 corrosion2 Δ Frequently broken 29 39 ◯ Al core was No corroded by 35 corrosion3 X No. 2 was subjected to T6 treatment Cannot Cannot -- -- -- (500° C. → water · cooled → 170° C. × be be 10 Hr), but embrittled and broken. measured measured4 Δ Frequently broken 27 40 ◯ Al core was No corroded by 3 corrosion5 Δ Frequently broken 36 49 ◯ Al core was No corroded by 25 corrosion6 Δ Frequently broken 29 37 ◯ Al core was No corroded by 9 corrosion7 X No. 6 was subjected to T6 treatment Cannot Cannot -- -- -- (500° C. → water · cooled → 170° C. × be be 10 Hr), but embrittled and broken. measured measured(8) ◯ Good drawability 48 81 ◯ Al core was No corroded by 0.8 corrosion(9) ◯ Good drawability 47 80 ◯ Al core was No corroded by 1.0 corrosion10 ◯ Good drawability 54 98 Δ Cu layer Al core was No easy to corroded by 0.8 corrosion break11 Δ Frequently broken 28 40 ◯ Al core was No corroded by 4.5 corrosion12 ◯ Good drawability, but not light 40 71 ◯ Al core was No corroded by 0.8 corrosion13 X Poor drawability 75 105 X ◯ No corrosion14 Δ Frequently broken, T6 treatment done. After T6 69 X Corroded along Same as left treatment total length with no 50 trace of original form.15 ◯ Good drawability, but heavy 46 40 ◯ ◯ No corrosion__________________________________________________________________________ Note: Nos. (8) and (9) are Cu/Al composite wires of the invention. Nos. 13, 14 and 15 are comparative singlestrand wire samples.
An ordinary electric conductor whose total cross-sectional area was from 0.34 to 0.5 mm 2 such as shown in FIG. 5 was prepared by stranding a total of 19 single solid conductors of each of the Cu/Al composite wires of the invention (Nos. 8 and 9), the Cu/Al composite wires (Nos. 10 and 12), the duralumin wire (NO. 14) and the tough-pitch copper wire (No. 15) as comparative examples. The mechanical properties of these electric wires are shown in Table 2.
While the tensile load (kgf) and soldering test conditions are the same as applied to the single wires, the bending test and salt spray test conditions were the same except that the weight was 1 kg in the bending test and the ends were covered with waterproof caps in the salt spray test.
TABLE 2__________________________________________________________________________ Conduc- Tensile Salt spray Outside tivity load Number character- diameter (%/ (kgf/ Weight of Solder- isticNo. Material of conductor Makeup (mm) IACS) mm.sup.2) (g/m) bendings ability (Surface)__________________________________________________________________________Wires 8 Cu/Al composite wire 19 conduc- 0.76 52 17.8 1.66 415 ◯ ◯of tors/0.15 mmφthe 9 " 19 conduc- " " 17.0 1.59 403 ◯ ◯inven- tors/0.15 mmφtionCompara- 12 " 19 conduc- " 60 14.9 1.96 360 ◯ ◯tive tors/0.15 mmφwires 14 Duralumin 19 conduc- " 40 17.5 1.04 348 X X tors/0.15 mmφ 15 Tough-pitch copper 19 conduc- " 99 16.8 3.29 359 ◯ ◯ tors/0.15 mmφ 10 Cu/Al composite wire 19 conduc- " 38 19.8 1.37 501 Δ X tors/0.15 mmφ__________________________________________________________________________
As is apparent from Table 1, the Cu/Al composite wire of the invention is comparable to titanium wire with respect to the specific gravity. The wire of the invention is about half the weight of the single-strand copper wire with a satisfactory conductivity that is larger than single-strand titanium and duralumin wires.
The simple heat treatment at below 400° C. and drawing process contributes to making strength of the core material greater than that of the copper cladding layer, thus providing satisfactory drawability to produce wire whose diameter is 0.15 mmφ. In addition, the tensile strength is increased appropriately while ensuring acceptable bending resistance. This means that the composite wire of the invention is effective as a conductor used at locations to which bending and bending vibration are added.
Since the composite wire of the invention has such a ratio in cross-sectional area of the copper cladding layer to the core as to allow soldering heat to be released, thereby ensuring satisfactory soldering reliability.
It is found from Table 2 that the Cu/Al composite wire of the invention has the following advantages. Compared with the stranded tough-pitch copper wire (No. 15) as the ordinary electric wire in current use, the composite wire obtained by the invention not only has greater tensile strength and better bending resistance but also is lighter and equal in solderability and salt spray characteristic.
Since the No. 10 stranded Cu/Al composite wire had remarkably low conductivity and was thin because of the small Cu layer coverage, the Cu layer was damaged during stranding or handling, and the damaged portion was locally corroded or broken due to salt water spraying. Thus, this wire (No. 15) was unsuitable. The No. 12 stranded Cu/Al composite wire, because of the higher Cu layer coverage, is not only inferior to the tough-pitch copper wire in current use in terms of tensile load, but also heavier.
FIG. 7 shows the shield effects of the sample piece wires. It was found for the first time that the Nos. 8 and 9 Cu/Al composite wires shown in Table 1 exhibited a characteristic similar to copper wire in high frequencies.
Therefore, the Cu/Al composite wire of the invention is extremely effective when used in fields such as requiring a small diameter, a certain tensile strength, lightness (lighter than copper wire) and soldering reliability at end surfaces; e.g., internal conductors of coaxial cables, electromagnetic shield braided wire, voice cords for tweeters, wiring conductors for airplanes and automobiles, wiring conductors of domestic appliances such as portable VTRs and TV sets, magnet wire for motors, and the like.
Since long and continuous wire can be obtained by the invention, the Cu/Al composite wire may be used as a filler material for use in TIG (tungsten inert gas) and MIG (metal inert gas) cladding by welding. | 4y
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TECHNICAL FIELD
[0001] The present invention relates to a nematic liquid crystal composition having negative dielectric anisotropy (Δ∈), which is useful as an electro-optical liquid crystal display material, and a liquid crystal display element using this liquid crystal composition.
BACKGROUND ART
[0002] Vertical alignment type VA-LCD's using liquid crystal compositions having negative dielectric anisotropy (negative Δ∈) can express the black of coal-black, and therefore have an excellent display quality. Thus, as high contrast liquid crystal display devices, VA-LCD's have widely penetrated into the liquid crystal TV-centered market. Furthermore, recently, in addition to the active matrix driving systems that are represented by liquid crystal TV's and the like, even in the passive matrix driving systems that are used as display devices for in-vehicle applications or electric appliance applications, the employment of VA-LCD's is increasing. In regard to the liquid crystal TV applications, in order to realize smooth movie display performance, the gap between glass substrates tends to be narrowed, while the birefringence (Δn) of the liquid crystal material tends to increase. On the other hand, in regard to the in-vehicle display devices, in order to obtain satisfactory contrast even in high time-shared driving, namely high multiplex drive with a large display capacity, a liquid crystal composition having negative Δ∈ is required to have a large Δn that has not been conventionally found, and at the same time, the liquid crystal composition is also required to have a large absolute value of Δ∈ in order to cone with voltage lowering. Many liquid crystal compounds and liquid crystal compositions have been suggested as liquid crystal materials for VA-LCD's; however, in order to increase Δn, it is necessary to increase the content of a liquid crystal compound having a large Δn in the liquid crystal composition, and in order to increase the absolute value of Δ∈, it is necessary to increase the content of a liquid crystal compound having a large absolute value of Δ∈ in the liquid crystal composition. However, when the contents of these compounds are increased, viscosity (η) is deteriorated, and consequently, the response speed is deteriorated.
[0003] Liquid crystal compositions which exhibit negative values of Δ∈ and large values of Δn have been hitherto disclosed (Patent Literatures 1 to 4). However, the liquid crystal composition described in Patent Literature 1 contains a liquid crystal compound having positive Δ∈, and the absolute value of Δ∈ is small. Furthermore, the liquid crystal compositions described in Patent Literatures 2 to 4 are such that the absolute value of Δ∈ is large but the value of Δn is not sufficiently large. Also, the liquid crystal compositions have large values of η.
[0004] Therefore, there is a demand for a liquid crystal composition which has a large absolute value of Δ∈ and a large value of Δn but a small value of η.
CITATION LIST
Patent Literature
[0000]
Patent Literature 1: Japanese Patent Application Laid-Open (JP-A) No. 11-228966
Patent Literature 2: JP-A No. 11-140447
Patent Literature 3: JP-A No. 2001-354967
Patent Literature 4: JP-A No. 2000-96058
SUMMARY OF INVENTION
Technical Problem
[0009] An object of the present invention is to provide a liquid crystal composition in which deterioration of viscosity associated with an increase in Δn and an increase in Δ∈ is suppressed, and to provide a liquid crystal display element having an improved response speed, by using the relevant liquid crystal composition.
Solution to Problem
[0010] The inventors of the present invention conducted a thorough investigation in order to solve the problems described above, and as a result, they found that the problems are solved by a combination of at least two or more kinds of particular compounds. That is, there are provided a liquid crystal composition containing, as a first component, one kind or two or more kinds of compounds selected from compounds represented by Formula (I):
[0000]
[0011] wherein R 11 and R 12 each independently represent an alkyl group having 1 to 8 carbon atoms, an alkoxy group having 1 to 8 carbon atoms, or an alkenyl group having 2 to 8 carbon atoms, while these groups are each independently unsubstituted or have at least one halogen group as a substituent, and one or two or more of —CH 2 — present in these groups may be each independently substituted by —O—, —S—, —CO—, —COO—, —OCO— or —OCO—C— such that oxygen atoms are not directly bonded to each other;
[0012] A 11 and A 12 each independently represent a group selected from the group consisting of:
[0013] (a) a trans-1,4-cyclohexylene group (wherein one —CH 2 — or non-adjacent two or more of —CH 2 —, which are present in this group, may be substituted by —O— and/or —S—,
[0014] (b) a 1,4-phenylene group (wherein one —CH═ or non-adjacent two or more of —CH═ groups, which are present in this group, may be substituted by —N═), and
[0015] (c) 1,4-cyclohexenylene, 1,4-bicyclo(2.2.2) octylene, piperidine-1,4-diyl, naphthalene-2,6-diyl, decahydronaphthalene-2,6-diyl, or 1,2,3,4-tetrahydronaphthalene-2,6-diyl,
[0016] while the hydrogen atoms on the group (a), group (b) and group (c) may be each independently substituted by an alkyl group having 1 to 3 carbon atoms, an alkenyl group having 2 or 3 carbon atoms, an alkoxy group having 1 to 3 carbon atoms, an alkenyloxy group having 1 to 3 carbon atoms, CN or halogen;
[0017] Z 11 and Z 12 each independently represent —COO—, —OCO—, —CH 2 O—, —OCH 2 —, —CF 2 O—, —OCF 2 —, —CH 2 CH 2 —, —CH═CH—, —C≡C—, —(CH 2 ) 4 —, —CH═CH—CH 2 CH 2 —, —CH 2 —CH 2 —CH═CH—, or a single bond;
[0018] a 11 and a 12 each independently represent 0 or 1; and
[0019] as a second component, one kind or two or more kinds of compounds selected from compounds represented by Formulas (II) and (III):
[0000]
[0020] wherein R 21 , R 22 , R 31 and R 32 each independently represent an alkyl group having 1 to 8 carbon atoms, an alkoxy group having 1 to 8 carbon atoms, or an alkenyl group having 2 to 8 carbon atoms, while these groups are each independently unsubstituted or have at least one halogen group as a substituent, and one or two or more of —CH 2 — present in these groups may be each independently substituted by —O—, −S—, —CO—, —COO—, —OCO— or —OCO—O— such that oxygen atoms are not directly bonded to each other;
[0021] A 21 , A 22 , A 23 , A 31 , A 32 and A 33 each independently represent a group selected from the group consisting of:
[0022] (a) a trans-1,4-cyclohexylene group (wherein one —CH 2 — or non-adjacent two or more of —CH 2 —, which are present in this group, may be substituted by —O— and/or —S—,
[0023] (b) a 1,4-phenylene group (wherein one —CH═ or non-adjacent two or more of —CH═ groups, which are present in this group, may be substituted by —N═), and
[0024] (c) 1,4-cyclohexenylene, 1,4-bicyclo(2.2.2)octylene, piperidine-1,4-diyl, naphthalene-2,6-diyl, decahydronaphthalene-2,6-diyl, or 1,2,3,4-tetrahydronaphthalene-2,6-diyl,
[0025] while the hydrogen atoms on the group (a), group (b) and group (c) may be each independently substituted by an alkyl group having 1 to 3 carbon atoms, an alkenyl group having 2 or 3 carbon atoms, an alkoxy group having 1 to 3 carbon atoms, an alkenyloxy group having 1 to 3 carbon atoms, CN or halogen;
[0026] Z 21 , Z 22 , Z 23 , Z 31 , Z 32 and Z 33 each independently represent —COO—, —OCO—, —CH 2 —, —OCH 2 —, —CF 2 O—, —OCF 2 —, —CH 2 CH 2 —, —CH═CH—, —C≡C—, —(CH 2 ) 4 —, —CH═CH—CH 2 —CH 2 —, —CH 2 CH 2 —CH═CH—, or a single bond; and
[0027] a 21 , a 22 , a 31 and a 32 each independently represent 0 or 1,
[0028] and a liquid crystal display element including the relevant liquid crystal composition as a constituent member.
Advantageous Effects of Invention
[0029] The liquid crystal composition of the present invention has features of a large value of Δn, negative Δ∈, and large absolute values thereof. Also, the liquid crystal composition has low η, has excellent liquid crystal properties, and exhibits a liquid crystal phase that is stable in a wide temperature range. Furthermore, since the liquid crystal composition is chemically stable to heat, light, water and the like, it is a liquid crystal composition that is capable of low voltage driving, and is practically useful and highly reliable.
DESCRIPTION OF EMBODIMENTS
[0030] In regard to the compound represented by Formula (I) as a first component, R 11 and R 12 each independently represent an alkyl group having 1 to 8 carbon atoms, an alkoxy group having 1 to 8 carbon atoms, an alkenyl group having 2 to 8 carbon atoms, or an alkenyloxy group having 2 to 8 carbon atoms; however, an alkyl group having 1 to 5 carbon atoms, an alkoxy group having 1 to 5 carbon atoms, an alkenyl group having 2 to 5 carbon atoms, or an alkenyloxy group having 2 to 5 carbon atoms is preferred, and a linear group is preferred, a 11 represents 0 or 1; however, in the case where a high response speed is considered important, 0 is preferred, while in the case where the nematic phase upper limit temperature is considered important, 1 is preferred. Also, in the case where having a large value of Δn is considered important, 1 is preferred. A 11 and A 12 each independently represent any one of:
[0000]
[0031] and one or two or more hydrogen atoms present on the benzene rings may be substituted by halogen. However, a 1,4-phenylene group or a 1,4-cyclohexylene group are preferred, and the 1,4-phenylene group may be substituted with one or two or more fluorine atoms. A 11 , if present, is more preferably a 1,4-cyclohexylene group when viscosity is considered important, and A 12 is more preferably a 1,4-phenylene group when refractive index anisotropy is considered important.
[0032] More specifically, the compound represented by Formula (I) is preferably a compound represented by any one of the following Formulas (I-1) to (I-3):
[0000]
[0033] wherein R 11 has the same meaning as R 11 in Formula (I); and R 12 has the same meaning as R 12 in Formula (I)
[0034] In regard to the compounds represented by Formulas (II-1) and (II-2) as a second component, one kind or two or more kinds of compounds represented by Formula (II-1) only may be used, one kind or two or more kinds of compounds represented by Formula (II-2) may be used, or mixtures of one kind or two or more kinds of compounds represented by Formula (II-1) and one kind or two or more kinds of compounds represented by Formula (II-2) may also be used.
[0035] It is preferable that the compound represented by Formula (I) be contained in an amount of at least 2% by weight or more, but it is more preferable that the compound be contained in an amount of 2% by weight to 70% by weight, and even more preferably 2% by weight to 40% by weight.
[0036] Regarding the compounds represented by Formulas (II-1) and (II-2), R 21 , R 22 , R 31 and R 32 each independently represent an alkyl group having 1 to 8 carbon atoms, an alkoxy group having 1 to 8 carbon atoms, an alkenyl group having 2 to 8 carbon atoms, or an alkenyloxy group having 2 to 8 carbon atoms. However, an alkyl group having 1 to 5 carbon atoms, an alkoxy group having 1 to 5 carbon atoms, an alkenyl group having 2 to 5 carbon atoms, or an alkenyloxy group having 2 to 5 carbon atoms is preferred, and a linear group is preferred. a 21 , a 22 , a 31 and a 32 each independently represent 0 or 1; however, a 21 +a 22 is preferably 0 or 1, and a 21 +a 22 is preferably 0 in the case where a high response speed is considered important, while a 21 +a 22 is preferably 1 in the case where the nematic phase upper limit temperature is considered important, a 31 +a 32 is preferably 0 or 1, and a 31 +a 32 is preferably 0 when a high response speed is considered important, while a 31 +a 32 is preferably 1 when the nematic phase upper limit temperature is considered important. Z 21 , Z 22 , Z 31 and Z 32 each independently represent a single bond, —CH═CH—, —C≡C—, —CH 2 O—, —OCH 2 — or —CH 2 CH 2 —, but a single bond, —CH 2 O—, —OCH 2 — or —CH 2 CH 2 — is preferred. A 21 , A 22 , A 23 , A 31 , A 32 and A 33 each independently represent any one of the following:
[0000]
[0037] but one or two or more hydrogen atoms present on the benzene ring may be substituted by halogen. However, a 1,4-phenylene group or a 1,4-cyclohexylene group is preferred, and the 1,4-phenylene group may be substituted with one or two or more fluorine atoms. If viscosity is considered important, a 1,4-cyclohexylene group is preferred.
[0038] More specifically, the compounds represented by Formulas (II) and (III) are preferably compounds represented by the following Formulas (II-1) to (III-3):
[0000]
[0039] wherein R 21 has the same meaning as R 21 in formula (II); R 22 has the same meaning as R 22 in Formula (II); R 31 has the same meaning as R 31 in Formula (III); and R 32 has the same meaning as R 32 in Formula (III).
[0040] Furthermore, in the compounds represented by Formulas (II-1) and (II-3), R 21 is preferably an alkyl group or an alkenyl group, R 22 is preferably an alkyl group or an alkenyl group. Furthermore, in the compound represented by Formula (II-1), R 21 is preferably an alkenyl group, and R 22 is preferably an alkyl group. In the compound represented by Formula (II-3), R 21 is preferably an alkenyl group, and R 22 is preferably an alkyl group. In the compounds represented by Formulas (II-2), (II-4) and (II-5), R 21 is preferably an alkyl group or an alkenyl group, and R 22 is preferably an alkoxy group or an alkenyloxy group. Furthermore, in the compound represented by Formula (II-2), R 21 is preferably an alkenyl group, and R 22 is preferably an alkenyloxy group. In the compound represented by Formula (I-1-4), R 21 is preferably an alkyl group, and R 22 is preferably an alkoxy group. In the compound represented by Formula (II-5), R 21 is preferably an alkyl group, and R 22 is preferably an alkoxy group. In the compounds represented by Formulas (III-1), (III-2) and (III-3), R 31 is preferably an alkyl group or an alkenyl group, and R 32 is preferably an alkoxy group or an alkenyloxy group. Furthermore, R 31 is preferably an alkyl group, and R 32 is preferably an alkoxy group.
[0041] At least one or more kinds of compounds selected from the compounds represented by Formulas (II) and (III) are used. However, it is more preferable to use two or more kinds, and it is even more preferable to use three or more kinds.
[0042] The compound represented by Formula (IV), which is a third component, is a compound having a value of Δ∈ close to zero, and may have an electron-withdrawing group in the molecule. However, it is preferable that the number of the electron-withdrawing group be 2 or less, and preferably one or less, and it is more preferable that the compound contain no electron-withdrawing group.
[0000]
[0043] R 41 and R 42 each independently represent an alkyl group having 1 to 8 carbon atoms, an alkoxy group having 1 to 8 carbon atoms, an alkenyl group having 2 to 8 carbon atoms, or an alkenyloxy group having 2 to 8 carbon atoms. However, an alkyl group having 1 to 5 carbon atoms, an alkoxy group having 1 to 5 carbon atoms, an alkenyl group having 2 to 5 carbon atoms, or an alkenyloxy group having 2 to 5 carbon atoms is preferred, and a linear group is preferred.
[0044] A 41 , A 42 and A 43 each independently represent any one of the following:
[0000]
[0045] but a 1,4-phenylene group or a 1,4-cyclohexylene group is preferred, and the 1,4-phenylene group may be substituted with one or two or more fluorine atoms or methyl groups. A 41 , A 42 and A 43 are not intended to represent a 2,3-dihalo-1,4-phenylene group.
[0046] Z 41 and Z 42 each independently represent a single bond, —C≡C—, —C═N—N═C—, —CH═CH—, —CF═CF—, —CF 2 O—, —OCF 2 —, —COO— or —OCO—; however, a single bond, —CH 2 CH 2 —, —C≡C—, —COO— or —OCO— is preferred, and a single bond or —C≡C— is preferred. a 41 represents 0, 1 or 2, but 0 or 1 is preferred. When plural A 42 's are present, they may be identical or different from each other, and when plural Z 42 's are present, they may be or different from each other.
[0047] More specifically, the compound represented by Formula (IV) is preferably a compound represented by any one of the following formulas (IV-1) to (IV-10):
[0000]
[0048] wherein R 41 has the same meaning as R 41 in Formula (IV) and R 42 has the same meaning as R 42 in Formula (IV).
[0049] Regarding the compound represented by Formula (IV), it is preferable that one kind to ten kinds of such compounds be contained, and it is particularly preferable that two kinds to eight kinds of such compounds be contained. The lower limit of the content of the compound represented by Formula (IV) is preferably 5% by mass, more preferably 10% by mass, even more preferably 20% by mass, and particularly preferably 30% by mass. The upper limit is preferably 80% by mass, more preferably 70% by mass, and even more preferably 60% by mass.
[0050] When the present invention is used in an active matrix-driven liquid crystal display element, the nematic phase-isotropic liquid phase transition temperature (T ni ) is preferably 60° C. to 120° C., and the lower limit is more preferably 65° C., and particularly preferably 70° C. The upper limit is more preferably 90° C., and particularly preferably 80° C. It is preferable that Δ∈ at 25° C. be from −2.0 to −6.0, and Δ∈ is more preferably from −2.5 to −5.0, and particularly preferably from −2.5 to −3.5. Δn at 25° C. is preferably 0.08 to 0.13, but more preferably 0.09 to 0.12. To be more specific, in the case of dealing with a small cell gap, Δn is preferably 0.10 to 0.12, and in the case of dealing with a large cell gap, Δn is preferably 0.08 to 0.10. The viscosity at 20° C. is preferably 10 mPa·s to 30 mPa·s, but the viscosity is more preferably 10 mPa·s to 25 mPa·s, and particularly preferably 10 mPa·s to 20 mPa·s.
[0051] Furthermore, when the present invention is used in a passive matrix-driven liquid crystal display element, for consumer use applications, T ni is preferably from 60° C. to 120° C., and the lower limit is more preferably 65° C., and particularly preferably 70° C. The upper limit is more preferably 90° C., and particularly preferably 80° C. For in-vehicle applications and the like, the lower limit is more preferably 90° C., and particularly preferably 100° C. The upper limit is more preferably 115° C., and particularly preferably 105° C. Δn at 25° C. is preferably from 0.08 to 0.13 for low duty driving, and particularly preferably from 0.08 to 0.11. Furthermore, Δn at 25° C. is preferably from 0.13 to 0.20 for high duty driving, and particularly preferably from 0.15 to 0.18. Δ∈ at 25° C. is preferably from −2.0 to −7.0 in low duty driving, and particularly preferably from −2.5 to −5.5. The viscosity at 20° C. is preferably from 10 mPa·s to 40 mPa·s, but the viscosity is more preferably from 10 mPa·s to 30 mPa·s, and particularly preferably from 10 mPa·s to 25 mPa·s.
[0052] The nematic liquid crystal composition of the present invention may also contain, in addition to the compounds described above, a conventional nematic liquid crystal, a smectic liquid crystal, a cholesteric liquid crystal, an oxidation inhibitor, an ultraviolet absorber, a polymerizable monomer, and the like.
[0053] The nematic liquid crystal composition of the present invention is useful for liquid crystal display elements, is useful for liquid crystal display elements for active matrix driving and liquid crystal display elements for passive matrix driving, and is particularly useful for liquid crystal display elements for passive matrix driving. Furthermore, the nematic liquid crystal composition of the present invention can be used in liquid crystal display elements for the VA mode, PSVA mode, IPS mod or ECB mode.
EXAMPLES
[0054] Hereinafter, the present invention will be described in more detail by way of Examples, but the present invention is not intended to be limited to these Examples. Furthermore, the unit “percent (%)” for the compositions of the following Examples and Comparative Examples means “percent (%) by mass”.
[0055] Examples of the present invention will be introduced below, but the present invention is not intended to be limited to these.
[0056] Terms used in the Examples will be described below.
[0057] T NI : Nematic-isotropic transition temperature [° C.]
[0058] Δn: Refractive index anisotropy (589 nm, 25° C.)
[0059] Δ∈: Dielectric anisotropy (1 KHz, 25° C.)
[0060] η: Bulk flow viscosity [mPa·s](20° C.)
[0061] Response speed: Injected into a vertical alignment cell with a gap of 3.5 μm and a pretilt angle of 89°, and measured with square waves at 5 V and 100 Hz
[0062] τon: Time taken for the change from transmittance 0% transmittance 90% [ms]
[0063] τoff: Time taken for the change from transmittance 100% to transmittance 10% [ms]
[0064] The brevity codes described below will be used for the description of compounds in the Examples.
[0065] Brevity codes for side chains will be shown blow.
[0066] -n (number): —C n H 2n+1 (the alkyl side chain will be expressed as a number, and a representative will be expressed as R).
[0067] -On: —OC n H 2+1
[0068] -ndm: —(C n H 2n+1 —C═C—(CH 2 ) m-1 )
[0069] ndm-: C n H 2n+1 —C═C— (CH 2 ) m-1 —
[0070] -nOm: —(CH 2 ) n OC m H 2m+1
[0071] nOm-: C n H 2n+1 O(CH 2 ) m —
[0072] -Od(m)n: —O(CH n H 2n+1 —C═C—(CH 2 ) m-2 )
[0073] d(m)nO-: C n H 2n+1 —C═C—(CH 2 ) m-2 O—
[0074] -Brevity codes for linking groups will be shown below.
[0075] -V-: —CO—
[0076] -VO-: —COO— (-E- is also possible)
[0077] -OV-: —OCO—
[0078] -1N-: —C═N—
[0079] -N1-: —N═C—
[0080] -T-: —C≡C—
[0081] -2-: —CH 2 CH 2 —
[0082] -3-: —CH 2 CH 2 CH 2 —
[0083] -4-: —CH 2 CH 2 CH 2 CH 2 —
[0084] -1O-: —CH 2 —O—
[0085] -O1-: —O—CH 2 —
[0086] -Z-: —CH═N—N═CH—
[0087] -G-: —CF═CF—
[0088] -D-: —CH═CH—
[0089] -2D-: —CH 2 CH 2 CH═CH—
[0090] -D2-: —CH═CHCH 2 CH 2 —
[0091] Brevity codes for substituents will be shown below.
[0092] -CN: —C≡N
[0093] -F: —F
[0094] -Cl: —Cl
[0095] OCFFF: OCF 3
[0096] CFFF: CF 3
[0097] OCFF: OCHF 2
[0098] O1CFFF: OCH 2 CF 3
[0099] Brevity codes for rings will be shown below.
[0000]
Examples 1 and 2
[0100] Nematic liquid crystal composition examples and the results for the measurement of property values will be described below.
Examples 1 and 2, and Comparative Example 1
[0101] Examples 1 and 2 are liquid crystal compositions containing compounds represented by Formula (I) and Formula (II-1), and Comparative Example 1 is a liquid crystal composition in which the compound represented by Formula (I) that is contained in Example 1 is replaced with a tolane derivative which is not substituted with fluorine atoms (3-Ph-T-Ph-O2 or the like). As compared with Comparative Example 1, Example 1 had a slight increase in viscosity, but the absolute value of Δ∈ became larger. Therefore, even if the content of the compound represented by Formula (II-1) is decreased, and the content of the so-called viscosity-reducing agent (although having a small absolute value of Δ∈, capable of lowering the viscosity of a liquid crystal composition when added thereto) is increased, a liquid crystal composition which exhibits a value of Δ∈ to the same extent as that of Comparative Example 1 can be prepared. In the liquid crystal composition described in this Example 2, the viscosity could be decreased to a large extent as compared with Comparative Example 1.
[0000]
TABLE 1
Comparative
Example 1
Example 1
Example 2
T NI
95.8
96.6
96.1
Δn
0.120
0.121
0.120
Δε
−2.7
−4.8
−2.8
η
44.5
48.7
26.2
0d1-Cy-Cy-5
7
0d1-Cy-Cy-3
12
12
20
3-Ph-T-Ph-O2
5
5-Ph-T-Ph-O1
5
3-Cy-Ph-T-Ph-2
5
4-Cy-Ph-T-Ph-1
5
0d1-Cy-Cy-Ph-1
11
11
10
0d3-Cy-Cy-Ph-1
11
11
14
0d1-Cy-1O-Ph5-O1-Cy-2
10
10
3
0d1-Cy-1O-Ph5-O1-Cy-3
10
10
3
0d1-Cy-1O-Ph5-O1-Cy-5
10
10
3
3-Ph-T-Ph5-O2
4
4
5-Ph-T-Ph5-O2
4
4
3-Cy-Ph-T-Ph5-O2
6
8
5-Cy-Ph-T-Ph5-O2
6
8
3-Cy-1O-Ph5-O1
8
8
8
3-Cy-1O-Ph5-O2
8
8
8
Examples 3 and 4, and Comparative Example 2
[0102] Examples 3 and 4 are liquid crystal compositions containing compounds represented by Formulas (I), (II-1) and (II-2), and Comparative Example 2 is a liquid crystal composition in which the compound represented by Formula (I) that is contained in Example 3 is replaced with a tolane derivative which is not substituted with fluorine atoms (3-Ph-T-Ph-O2 or the like). Similarly to the case of Examples 1 and 2 and Comparative Example 1, it was found that the viscosity was decreased to a large extent.
[0000]
TABLE 2
Comparative
Example 2
Example 3
Example 4
TNI
105.9
104.0
102.7
Δn
0.123
0.124
0.123
Δε
−3.1
−4.8
−3.2
η
40.8
43.4
27.5
0d1-Cy-Cy-5
6
0d1-Cy-Cy-3
20
20
20
3-Ph-T-Ph-O2
4
5-Ph-T-Ph-O1
4
3-Cy-Ph-T-Ph-2
4
4-Cy-Ph-T-Ph-1
4
0d1-Cy-Cy-Ph-1
12
12
14
0d3-Cy-Cy-Ph-1
15
15
15
3-Cy-1O-Nd4-O4
5
5
3
5-Cy-1O-Nd4-O2
5
5
3
5-Cy-1O-Nd4-O3
5
5
3
3-Cy-2-Cy-1O-Nd4-O2
5
5
3
2-Cy-Cy-1O-Nd4-O2
5
5
3
3-Ph-T-Ph5-O2
4
5
5-Ph-T-Ph5-O2
4
5
3-Cy-Ph-T-Ph5-O2
4
5
5-Cy-Ph-T-Ph5-O2
4
5
3-Cy-1O-Ph5-O1
6
6
5
3-Cy-1O-Ph5-O2
6
6
5
Examples 5 and 6, and Comparative Example 3
[0103] Examples 5 and 6 are liquid crystal compositions containing compounds represented by Formulas (I) and (II-1), and Comparative Example 1 is a liquid crystal composition in which the compound represented by Formula (II-1) that is contained in Example 1 is replaced with a compound which does not have a linking group in the molecule (3-Cy-Ph5-O2 or the like). As compared with Comparative Example 3, Example 5 had a slight increase in viscosity, but the absolute value of Δ∈ became larger. Therefore, even if the content of the compound represented by Formula (II-1) is decreased, and the content of the so-called viscosity-reducing agent (although having a small absolute value of Δ∈, capable of lowering the viscosity of a liquid crystal composition when added thereto) is increased, a liquid crystal composition which exhibits a value of Δ∈ to the same extent as that of Comparative Example 1 can be prepared. In the liquid crystal composition described in this Example 6, the viscosity could be decreased to a large extent as compared with Comparative Example 1.
[0000]
TABLE 3
Comparative
Example 3
Example 5
Example 6
T NI
107.1
106.9
106.8
Δn
0.129
0.126
0.127
Δε
−2.5
−3.0
−2.5
η
15.6
21.3
14.3
0d1-Cy-Cy-5
7
0d1-Cy-Cy-3
22
22
22
0d1-Cy-Cy-Ph-1
12
12
10
0d3-Cy-Cy-Ph-1
15
15
15
2-Cy-Cy-1O-Ph5-O2
9
8
3-Cy-Cy-1O-Ph5-O2
9
8
3-Cy-1O-Ph5-O1
9
4
3-Ph-T-Ph5-O2
6
6
7
5-Ph-T-Ph5-O2
6
6
7
3-Cy-Ph-T-Ph5-O2
6
6
6
5-Cy-Ph-T-Ph5-O2
6
6
6
3-Cy-Ph5-O2
9
2-Cy-Cy-Ph5-O2
9
3-Cy-Cy-Ph5-O2
9
Examples 7 and 8, and Comparative Example 4
[0104] Examples 7 and 8 are liquid crystal compositions containing compounds represented by Formulas (I) and (II-1) and Comparative Example 4 is a liquid crystal composition in which the compound represented by Formula (II-1) that is contained in Example 7 is replaced with a compound which does not have a linking group in the molecule (3-Cy-Ph5-O2 or the like). Similar to the case of Examples 5 and 6 and Comparative Example 3, it was found that the viscosity was decreased to a large extent.
[0000]
TABLE 4
Comparative
Example 4
Example 7
Example 8
T NI
113.8
114.3
109.3
Δn
0.126
0.125
0.126
Δε
−2.30
−2.66
−2.27
η
15.0
15.4
13.7
0d1-Cy-Cy-5
4
0d1-Cy-Cy-3
24
24
24
0d1-Cy-Cy-Ph-1
15
15
15
0d3-Cy-Cy-Ph-1
15
15
15
2-Cy-Cy-1O-Ph5-O2
12
9
3-Cy-Cy-1O-Ph5-O2
12
9
3-Ph-T-Ph5-O2
7
7
8
5-Ph-T-Ph5-O2
7
7
8
3-Cy-Ph-T-Ph5-O2
4
4
4
5-Cy-Ph-T-Ph5-O2
4
4
4
2-Cy-Cy-Ph5-O2
12
3-Cy-Cy-Ph5-O2
12
Examples 9 and 10, and Comparative Example 5
[0105] Examples 9 and 10 are liquid crystal compositions containing compounds represented by Formulas (I) and (II-2), and Comparative Example 5 is a liquid crystal composition in which the compound represented by Formula (I) that is contained in Example 9 is replaced with a tolane derivative which is not substituted with fluorine atoms (3-Ph-T-Ph-O2 or the like), and the compound represented by Formula (II-2) is replaced with a compound which does not have a linking group in the molecule (3-Cy-Ph5-O2 or the like). As compared with Comparative Example 5, Example 9 had a slight increase in viscosity, but the absolute value of Δ∈ became larger. Therefore, it was found that even if the contents of the compounds represented by Formulas (I) and (II-2) are decreased, and the content of the so-called viscosity-reducing agent (although having a small absolute value of Δ∈, capable of lowering the viscosity of a liquid crystal composition when added thereto) is increased, a liquid crystal composition which exhibits a larger absolute value of Δ∈ and a viscosity that is lower to a large extent as compared with Comparative Example 1 can be prepared, as is the case with the liquid crystal composition disclosed in Example 10.
[0000]
TABLE 5
Comparative
Example 5
Example 9
Example 10
T NI
120.1
115.5
114.5
Δn
0.120
0.136
0.124
Δε
−1.72
−5.81
−1.88
η
17.8
49.2
13.8
0d1-Cy-Cy-5
16
0d1-Cy-Cy-3
20
20
22
3-Ph-T-Ph-O2
6
5-Ph-T-Ph-O1
6
3-Cy-Ph-T-Ph-2
5
0d1-Cy-Cy-Ph-1
10
10
14
0d3-Cy-Cy-Ph-1
13
13
15
3-Cy-1O-Nd4-O4
7
5-Cy-1O-Nd4-O2
7
3
5-Cy-1O-Nd4-O3
7
2
3-Cy-2-Cy-1O-Nd4-O2
7
2
3-Cy-2-Cy-1O-Nd4-O3
6
2-Cy-Cy-1O-Nd4-O2
6
2
3-Ph-T-Ph5-O2
6
4
5-Ph-T-Ph5-O2
6
4
3-Cy-Ph-T-Ph5-O2
5
8
5-Cy-Ph-T-Ph5-O2
8
2-Cy-Cy-Ph5-O2
10
3-Cy-Cy-Ph5-O1
10
3-Cy-Cy-Ph5-O2
10
3-Cy-Cy-Ph5-O4
10
Examples 11 and 12, and Comparative Example 6
[0106] Examples 11 and 12 are liquid crystal compositions containing compounds represented by Formulas (I) and (II-1), and Comparative Example 6 is a liquid crystal composition in which the compound represented by Formula (II-1) that is contained in Example 11 is replaced with a compound which does not have a linking group in the molecule (2-Cy-Cy-Ph5-O2 or the like). Similarly to the case of Examples 9 and 10 and Comparative Example 5, it was found that the viscosity was decreased to a large extent.
[0000]
TABLE 6
Comparative
Example 6
Example 11
Example 12
T NI
112.8
111.5
113.3
Δn
0.119
0.115
0.118
Δε
−1.84
−3.67
−1.98
η
16.9
28.1
14.8
0d1-Cy-Cy-5
9
0d1-Cy-Cy-3
18
18
24
3-Ph-T-Ph-O2
5
5-Ph-T-Ph-O1
5
3-Ph-T-Ph-1
6
0d1-Cy-Cy-Ph-1
11
11
14
0d3-Cy-Cy-Ph-1
15
15
15
0d1-Cy-1O-Ph5-O1-Cy-2
14
6
0d1-Cy-1O-Ph5-O1-Cy-3
13
5
0d1-Cy-1O-Ph5-O1-Cy-5
13
5
3-Ph-T-Ph5-O2
3
3
5-Ph-T-Ph5-O2
3
3
3-Cy-Ph-T-Ph5-O2
5
8
5-Cy-Ph-T-Ph5-O2
5
8
2-Cy-Cy-Ph5-O2
10
3-Cy-Cy-Ph5-O1
10
3-Cy-Cy-Ph5-O2
10
3-Cy-Cy-Ph5-O4
10
Example 13 and Comparative Example 7
[0107] Example 13 is a liquid crystal composition containing compounds represented by Formula (I), Formula (II-1) and Formula (II-2), and Comparative Example 7 is a liquid crystal composition in which the compound represented by Formula (I) that is contained in Example 13 is replaced with a tolane derivative which is not substituted with fluorine atoms (3-Ph-T-Ph-1 or the like). These liquid crystal compositions have the values of T NI , Δn and Δ∈ matched. It was found that Example 13 had its viscosity greatly improved.
[0000]
TABLE 7
Comparative
Example 7
Example 13
T NI
102
102
Δn
0.180
0.180
Δε
−2.64
−22.70
η
31.0
22.3
0d1-Cy-Cy-5
4
14
1d3-Ph-T-Ph-1d3
17
10
3-Ph-T-Ph-1
10
6
0d1-Cy-Cy-Ph-1
10
14
0d3-Cy-Cy-Ph-1
7
10
3-Cy-Ph-T-Ph-2
6
4-Cy-Ph-T-Ph-1
6
3-Cy-Ph-T-Pa2-1
3
3-Cy-VO-Ph-T-Ph-1
2
3-Cy-1O-Nd4-O4
4
4
5-Cy-1O-Nd4-O2
4
3
5-Cy-1O-Nd4-O3
3
3
3-Cy-2-Cy-1O-Nd4-O2
3
2-Cy-Cy-1O-Nd4-O2
3
0d1-Cy-1O-Ph5-O1-Cy-2
9
0d1-Cy-1O-Ph5-O1-Cy-3
9
5
3-Ph-T-Ph5-O2
7
5-Ph-T-Ph5-O2
8
3-Cy-Ph-T-Ph5-O2
8
5-Cy-Ph-T-Ph5-O2
8
Example 14 and Comparative Example 8
[0108] Example 14 is a liquid crystal composition containing compounds represented by Formula (I), Formula (II-1) and Formula (II-2), and Comparative Example 8 is a liquid crystal composition in which the compound represented by Formula (I) that is contained in Example 14 is replaced with a tolane derivative which is not substituted with fluorine atoms (3-Ph-T-Ph-1 or the like). These liquid crystal compositions have the values of T NI , Δn and Δ∈ matched. It was found that Example 14 had its viscosity greatly improved.
[0000]
TABLE 8
Comparative
Example 8
Example 14
T NI
101.9
101.2
Δn
0.200
0.200
Δε
−2.72
−2.81
η
33.5
24.1
0d1-Cy-Cy-5
13
1d3-Ph-T-Ph-1d3
16
12
3-Ph-T-Ph-1
14
8
4-Ph-T-Ph-O2
3
0d1-Cy-Cy-Ph-1
12
8
1d3-Cy-Cy-Ph-1
4
3-Cy-Ph-T-Ph-2
6
4
4-Cy-Ph-T-Ph-1
6
4
3-Cy-Ph-T-Pa2-1
3
3-Cy-VO-Ph-T-Ph-1
6
3-Cy-1O-Nd4-O4
4
4
5-Cy-1O-Nd4-O2
4
4
5-Cy-1O-Nd4-O3
4
4
3-Cy-2-Cy-1O-Nd4-O2
3
2-Cy-Cy-1O-Nd4-O2
3
0d1-Cy-1O-Ph5-O1-Cy-2
8
0d1-Cy-1O-Ph5-O1-Cy-3
8
5
3-Ph-T-Ph5-O2
7
5-Ph-T-Ph5-O2
7
3-Cy-Ph-T-Ph5-O2
8
5-Cy-Ph-T-Ph5-O2
8
Examples 15 and 16
[0109] Example 15 is a liquid crystal composition having the value of Δn adjusted to be as low as 0.089, and Example 16 is a liquid crystal composition having the value of Δn adjusted to be as high as 0.200. Furthermore, liquid crystal compositions having large absolute values of Δ∈ in which the absolute values of Δ∈ were as large as 5.9 to 5.6, and voltage reduction could be achieved in a wide range of Δn, could be prepared. It was found that the liquid crystal compositions of the present invention can have the values of Δn and Δ∈ adjusted in accordance with various requirement characteristics, and low viscosity can be realized.
[0000]
TABLE 9
Example 15
Example 16
T NI
93.5
101.5
Δn
0.089
0.200
Δε
−5.90
−5.60
η
28.9
65.6
1d1-Cy-Cy-3
20
1d3-Ph-T-Ph-1d3
10
3-Ph-T-Ph-1
5
0d1-Cy-Cy-Ph-1
5
0d3-Cy-Cy-Ph-1
5
3-Cy-Ph-T-Ph-2
4
4-Cy-Ph-T-Ph-1
4
3-Cy-1O-Nd4-O4
5
5-Cy-1O-Nd4-O2
5
5-Cy-1O-Nd4-O3
5
0d1-Cy-1O-Ph5-O1-Cy-2
6
10
0d1-Cy-1O-Ph5-O1-Cy-3
15
11
0d1-Cy-1O-Ph5-O1-Cy-5
11
3-Ph-T-Ph5-O2
7
5-Ph-T-Ph5-O2
7
3-Cy-Ph-T-Ph5-O2
3
8
5-Cy-Ph-T-Ph5-O2
8
3-Cy-Cy-VO-Ph5-O2
10
3-Cy-1O-Ph5-O1
8
3-Cy-1O-Ph5-O2
10
2-Cy-Cy-1O-Ph5-O2
8
3-Cy-Cy-1O-Ph5-O2
10
Examples 17 to 19
[0110] Examples 17 to 19 are liquid crystal compositions in which T NI is as high as 104° C., and the values of Δn and Δ∈ are also respectively set to be high. It is usually difficult to obtain a liquid crystal composition which satisfies such requirement characteristics, but the present invention enables this. Furthermore, an increase in viscosity could also be suppressed.
[0000]
TABLE 10
Example 17
Example 18
Example 19
T NI
104.1
106.0
107.3
Δn
0.247
0.232
0.231
Δε
−6.9
−7.6
−7.7
η
48.8
51.1
41.2
1d3-Ph-T-Ph-1d3
5
3
3-Ph-T-Ph-1
5
2
6
0d1-Cy-Cy-Ph-1
5
3-Cy-1O-Nd4-O4
5
5-Cy-1O-Nd4-O2
5
5-Cy-1O-Nd4-O3
5
0d1-Cy-1O-Ph5-O1-Cy-2
10
0d1-Cy-1O-Ph5-O1-Cy-3
10
0d1-Cy-1O-Ph5-O1-Cy-5
5
3-Cy-1O-Ph5-O2
10
2-Cy-Cy-1O-Ph5-O2
6
3-Cy-Cy-1O-Ph5-O2
10
3-Ph-T-Ph5-O2
20
20
18
5-Ph-T-Ph5-O2
20
20
18
3-Cy-Ph-T-Ph5-O2
15
15
16
5-Cy-Ph-T-Ph5-O2
15
15
16 | 4y
|
FIELD OF THE INVENTION
This invention relates in general to the field of distributed information processing, resource allocation, computing and communications and more specifically to a system and method of organizing tuple spaces by synchronization to coordinate activities among multiple entities.
BACKGROUND OF THE INVENTION
Distributed information processing involves two or more processing entities under autonomous control or purpose which operate cooperatively to resolve a processing need. Such entities frequently operate within a system and are frequently subsets of larger systems tailored to address a specific processing aspect, but may originate remotely making demands on the local system. In complex systems, entities frequently compete and share resources within the environment and the operation of one entity may affect, degrade, inhibit, or even destabilize the operation of another. One of the problems in distributed information processing and computing is the coordination of activities among the various entities in the environment. While the coordination problem manifests itself in distributed environments, it also appears in other contexts such as integrated multi-component computing systems where coordination is required between multiple components which may reside within the same cabinet or in service environments where resources must be shared.
One example of this problem is the creation of features in telephone switching systems. Telephone switching systems are typically very large. They are implemented to provide many hundreds of features and consist of tens of millions of lines of code. These systems are not static. The developers of such systems are required by competitive pressures to add features on a regular basis. This presents the problem that the additional functions of new features interact with the functioning of features already present in the system. In the worst case, the newly added features can disable the functioning of an older feature, destabilize the system or create conditions which will confuse the user. Because of this problem, previous approaches have expended considerable effort during the development of new features to determine all possible interactions with all of the other features in the system. There have been many proposals to handle the problem of feature interaction in telephone systems. In one prior art system, Northern Telecom has developed a method in which models of call set up have been developed for the Intelligent Network and the Advanced Intelligent Network where features are constructed as separate state machines which interact by communication through a stack based mechanism to provide a degree of regularity in call processing.
A second example of the problem is the coordination and allocation of resources in the provisioning of a service, especially in real time environments where there are time and qualitative constraints. Where there are numerous applications that use a service, such as a printing service, and a number of print processes that serve requests, difficulty occurs in allocating resources to get the job done given the various priorities and quality requirements of each job and the current status and capability of each resource.
A third example of the problem is component coordination in multiple component systems. Component based hardware and software uses parts developed by different vendors. Vendors create components from parts developed by other vendors. When components are brought together, in some circumstances, they modify the behavior of other components. If the parts are static, with their behavior well known and not expected to change over the course of a component's lifetime, then it is possible to identify and resolve all possible component interactions at the time of the original system design. However, in this prior art approach, it is necessary to consider the behavior of any part in the presence of all the possible combinations of all other parts. When the number of parts becomes large, the task becomes enormous, and virtually impossible when components are not available and their behavior not known beforehand at design time, or the behavior can be changed or upgraded after the initial implementation.
The use of tuple spaces is also known in the art as a means of communication between entities. A tuple space is an instance of a blackboard architecture where there are knowledge sources or entities that invoke operations on the blackboard. In the prior art, knowledge sources communicate with the tuple space using a publish-subscribe mechanism. An entity in a prior art tuple space will publish the occurrence of its action or event such that other entities who subscribe become aware that the event has occurred. These prior art tuple spaces are event based and asynchronous. This means that the tuple space provides matching and processing of tuples on the occurrence of events. However, there are problems with prior art tuple spaces. The event based, asynchronous nature of prior art tuple spaces leads to complications in synchronization, maintaining of data integrity and potential dead-locks. There are no assurances that events will occur or means to communicate that the occurrence of an event is no longer relevant.
SUMMARY OF THE INVENTION
The present invention is designed to provide a system and method for coordinating activities of multiple entities in an information processing or computing environment where entity interaction and conflict can be detected and resolved during operation. It provides a mechanism by which entities can coordinate their activity through assertions in a special inventive tuple space. With the inventive system and method, entities need only be aware of the objective of other entities and not their respective detailed implementations. An entity can represent a hardware or software component or process, a knowledge source or feature thereof.
This invention is based on the coordination of entities by assertions in a shared synchronized tuple space to with which an entity communicates and has access. Entities operate in a permission-action loop. This is in contrast to the publish-subscribe nature of prior art tuple spaces. An entity in an information environment that is in charge of an activity will decide to perform an action in furtherance of the activity. This entity will form an “intention” to perform this action. The ‘intention’ contains the semantic value of the action with regard to the activity. Before proceeding with the action, the entity will place this intention as an assertion within a tuple space. Other entities which have an interest in this sort of intention about the activity can monitor the tuple space so that they will be informed of such intentions. They can then respond to the original entity with their comments about the intention. In effect, with knowledge about the state of the activity, the other entities act as advisors to the original entity. Thus, the original entity forms an intention about how to proceed with the activity and asks permission of other entities (the lack of which can be overridden) before it proceeds. In this manner, new entities, features, knowledge sources, processes or components can interact with previous ones before activities dangerous to the operation of the system are undertaken in a manner to ensure that system degradation or failure does not occur. The present invention is particularly useful for application to the call processing environment, although it is obvious to one skilled in art that the invention is not limited to that application.
Therefore, according to one aspect of the present invention there is provided: a system for controlling and coordinating activities among entities in an information and process environment comprising: a) a communications pathway for transmitting and receiving communications of the entities; and a shared memory connected to the communications pathway for maintaining a tuple space on which the entities post and receive messages synchronized to discrete time intervals.
According to a further aspect of the present invention there is provided: a method for controlling and coordinating activities among entities in an information and process environment comprising the steps of: a) providing a communications pathway for transmitting and receiving communications of the entities; b) providing a tuple space in a shared memory adapted for operation in discrete time intervals connected to the communications pathway; and c) posting and receiving messages of the entities to and from said tuple space synchronized to the discrete time intervals.
According to another aspect of the present invention there is provided: a method of call processing comprising the steps of: a) providing entities representative of call processing features; b) providing a communications pathway for transmitting and receiving communications of the entities; c) providing a tuple space in a shared memory adapted for operation in discrete time intervals connected to the communications pathway; d) requesting advice by a first of the entities desirous of taking action of other entities before taking the action by posting messages communicated on the tuple space to the other entities through the pathway; e) providing advice as desired by the other entities responsive to the messages by posting responding messages communicated on the tuple space to the first of the entities; f) evaluating the responding messages, if any, by the first of the entities; and g) taking advised action by the first of the entities after evaluating the responding messages.
According to another aspect of the present invention there is provided: a method for providing services in an automated contract environment comprising the steps of: a) providing a communications pathway for transmitting and receiving communications of application entities and service entities; b) providing a tuple space in a shared memory adapted for operation in discrete time intervals connected to the communications pathway; and c) posting and receiving messages of the application entities and the service entities to and from the tuple space synchronized to the discrete time intervals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a representative diagram of the synchronized tuple space of the present invention;
FIG. 2 is a representative schematic drawing illustrating the operation of the synchronized tuple space of the present invention through a first time slice in a call processing environment;
FIG. 3 is a representative schematic drawing illustrating the operation of the synchronized tuple space of the present invention through a second time slice in a call processing environment;
FIG. 4 is a representative schematic drawing illustrating the operation of the synchronized tuple space of the present invention through a third time slice in a call processing environment;
FIG. 5 is a representative schematic drawing illustrating the operation of the synchronized tuple space of the present invention through a fourth time slice in a call processing environment;
FIG. 6 is a representative schematic drawing illustrating the operation of the synchronized tuple space of the present invention through a fifth time slice in a call processing environment;
FIG. 7 is a representative schematic drawing illustrating the operation of the synchronized tuple space of the present invention through a sixth time slice in a call processing environment;
FIG. 8 is a representative schematic drawing illustrating the operation of the synchronized tuple space of the present invention through a seventh time slice in a call processing environment; and
FIG. 9 is a representative schematic drawing of an alternate embodiment of the synchronized tuple space of the present invention in a contract environment in the operation of a printing service.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to FIG. 1 , a tuple space 100 of the present invention is shown. The tuple space 100 illustrates an inventive modified implementation of a blackboard architecture. Traditional blackboard architectures are well known in the art. Blackboard architectures and systems have been described in the publications “Blackboard Systems”, by Daniel Corkill, published in AI Expert, September 1991, pp 41–47, “Blackboard Systems: The Blackboard Model of Problem Solving and the Evolution of Blackboard Architectures” by H. Penny Nii, Published in The AI Magazine, Summer 1986, pp. 38–53, and “Elevator Scheduling System Using Blackboard Architecture”, by Grantham K. H. Pang, published in IEEE Proceedings-D, Vol. 138, No. 4, July 1991, pp- 337–346.
One feature of the present invention is that the tuple space 100 has been inventively modified to be synchronized which allows for the timely and orderly processing of tuples. The tuple space 100 is synchronized with a clock that defines time slices as reference points for operation on the tuple space 100 . Tuple-space operations on the inventive tuple space 100 use an additional parameter, that is, number of time slices that the operation pertaining to the tuple remains in effect (time-slice counter). The synchronized tuple space 100 of the present invention provides a regular structure which can be used to help remove the complexity of interaction among multiple entities such as entities 102 . Entities 102 have a communications link and shared access to tuple space 100 . With the inventive system and method, entities 102 need only be aware of the objective of other entities and not their respective detailed implementations. In this manner, entities 102 can communicate through the tuple space 100 even if they do not know of each other beforehand. This facilitates a method of system operation through the use of tuple space 100 whereby loosely coupled entities 102 can operate cooperatively and new system features and components can interact and be added in an evolutionary manner. Entity 102 is communications enabled and may be a physical device, functional element, a hardware or software component or process, a program or application, component, knowledge source or feature, or a higher level abstraction thereof embodied in physical devices or applications operating in an intelligent manner. Entities might be represented or embodied as agents.
In the architecture employing tuple space 100 , one or more entities 102 communicate through and invoke operations in the tuple space 100 .
In prior art systems, only an anti-tuple is used to assess the current contents of a tuple space. In contrast, in the present invention, the assertion tuple is placed in the system in addition to anti-tuples to collect the responses. The asserting entity will wait a period of time set as a number of time slices of the tuple space for collecting the tuples sent in reply by any and all entities that desire to reply. At the end of that time period, the collecting tuples are removed and all reply tuples received after that period will be ignored and discarded. This mechanism resolves a prior art problem of requiring an entity to explicitly retract an unanswered tuple. The waiting period synchronizes the collection of reply tuples and provides a discrete amount of time for responses creating the synchronization of the tuple space 100 . The time period used for synchronization is adjustable and can be set as the same period for all assertions and contemporaneous for all assertions. This facilitates one implementation of the tuple space 100 in hardware memory application under processor control or in an ASIC. However, the invention is not limited in this manner and nothing precludes an asserting tuple from using any time period which is deemed suitable according to the required circumstances.
Tuple space 100 has shared data storage that facilitates content based addressing of its content accessible to the entities. Tuple space 100 may be implemented in memory running as a process or application on a processor, or on an ASIC, EPROM in any such other equivalent form as obvious to one skilled in the art. Processes and applications described herein are comprised of software written in any compatible language executed on a processor such as is well known in the art, which includes any required program and data storage apparatus, such as random access or disk memories. Applications or processes may be stored as software in memory operating under control of a processor. The invention is not limited to any particular physical device and it is obvious to one skilled in the art that the present invention can be adapted for embodiment in personal computers, servers, printers, telephones, switches, networks, data storage equipment, data transmission equipment or virtually any electronic or intelligent or intelligently controlled equipment.
Each entity 102 has a communications path 104 which may be a network, or a bus architecture for placing tuples on tuple space 100 and a similar communications path 106 for retracting tuples from tuple space 100 . Entities 102 interact with tuple space 100 using a permission/action mechanism. The permission/action loop mechanism exemplifies why this is a synchronized tuple space. All entities 102 must obey a convention for interaction that is carried out by the synchronized tuple space 100 . The convention is: “an entity that intends to perform an action that involves a significant change in the environment solicits advice for permission for the action during a specified number of time slices before the entity can proceed with the action” This convention breaks with the traditional view on encapsulation in software. The traditional view requires all the decision making to be encapsulated within the part itself. It should be noted that entities 102 are merely seeking advice for permission, which can be overridden in special or exceptional circumstances. But generally, entities 102 should comply with the convention.
Using communication paths 104 and 106 , entities 102 post and communicate messages in the form of asserting and removing tuples and anti-tuples containing ingles from tuple space 100 . The functions of entities 102 and tuple space 100 may be performed, coordinated or facilitated by agents. Tuple space 100 is configured with pre-defined sets of tuple formats specific to the purpose of the tuple space 100 as well as operations or commands to be performed on tuples. Likewise, each entity 102 , when initialized, is informed of the pre-defined sets of commands and the pre-defined tuple formats for interaction with the tuple space 100 . The pre-defined sets of tuple formats and the operations or commands form an ontology for communications on the tuple space 100 . The ontology is followed by all entities interacting with the tuple space 100 . The ontology is specific to the circumstances and to the particular tuple space 100 and provides the common means of communicating for entities 100 . The ontology, which may be viewed as a business rule engine, provides system designers and software engineers a method of resolving the distributed information processing and multi-component computing coordination and feature interaction problem as illustrated in further detail below.
Tuples, placed in the tuple space 100 are type-value pairs called ingles. Each ingle consist of a type (say Name) and a value (say John Doe). The following is an example of a tuple in a pre-defined format which would describe an employee for a company.
{name John Doe:age 37:employee_number 12345:start_date 810126:position T12}
The tuple space 100 enables coordination among entities by allowing queries based on the matching of tuples by anti-tuples. An anti tuple is a tuple in which can be used as a query in the tuple space 100 . In form, it is identical to a tuple except that the value of any or all fields may be replaced by a “?” which indicates a “don't care” condition. Tuple space 100 matches and returns all tuples with anti-tuples which agree in all fields except for that one indicated by the ? query. Thus the anti tuple:
{:name?:age 37:employee_number?:start_date?:position T12}
would return the tuples for all employees of position T12 who are 37 years old. In a preferred embodiment, this is set up as a function or procedure call through a suitably defined interface for the request and return of tuples.
As mentioned above, the tuple space 100 has pre-defined operations or commands that change state of the tuple space. For example, typical operations or commands are defined as:
a) out—This command “asserts” or places a tuple on the tuple space 100 . The duration for the tuple set as a number of time slices of the tuple space may be specified for how long this tuple should remain in the tuple space. This may be any period up to indefinite. b) in—This command queries with an anti-tuple and retracts a tuple from the tuple space 100 . In this case, a tuple which matches the parameters of the “in” command identifies the tuple to be retracted. This command is typically used in association with the “out” command by the same calling entity, although this is not required. If there is no matching tuple present on the tuple space 100 , then the operation of the calling entity blocks on the process that performs the “out” operations. The process of the calling entity is resumed once a matching tuple has arrived on the tuple space 100 . The retracted tuple is then returned to the procedure or entity that invoked the operation, or is discarded. A duration set as a number of time slices may be specified to last for any period up to indefinite. Copies of matching tuples will be returned through the interface to the calling entity and the tuples will be removed from the tuple space 100 . c) rd (read)—This command reads the tuple space 100 with an anti-tuple. It does the same as “in” operation but does not retract the tuple. A duration set as a number of time slices may be specified to last for any period up to indefinite. Copies of matching tuples will be returned through the interface and the tuples will remain in the tuple space 100 . d) Cancel—This operation can be introduced to cancel pending “rd” and “in” requests. It does not require the time-slice counter. Tuple-space matches cancel operations to all pending “in” and “rd” requests. Matched requests are terminated.
The “rd” or “in” operations or commands block their own operation until a tuple that matches the request arrives on the tuple space 100 . However, the work of the tuple space 100 carries on. After a matching tuple is recovered, the entity unblocks its activity and processes the tuple.
Tuple space 100 provides the matching synchronously with a clock that defines time slices for the frequency of matching. All “rd” and “in” requests are matched to the current content of the tuple space at the time when tuple space 100 receives notification of the end of the time slice. At that time following happens:
all “cancel” operations are performed; all pending “rd” and “in” are evaluated. All matches accumulated during last time slice are dispatched to originators of “rd” and “in” requests. all tuples matching pending “in” requests are garbage-collected; time-slice counter for all “rd”, “in” and “out” operations decrements; all elapsed “rd” and “in” requests are garbage-collected; all elapsed tuples are garbage-collected.
Each entity is aware of the duration of one time slice of the tuple-space 100 and coordinates its operation as multiples of time-slice duration. The time slices facilitate synchronization and create rates at which entities supply and retract information from the shared tuple-space 100 . Time slices may be of any duration, but are typically a function of the characteristics of the hardware and the nature of the communications system and environment.
It is possible for more than one entity to process the same tuple. When multiple entities process a tuple, it is important that the tuple that triggered unblocking was retracted by exactly one of the entities. This creates complex situations which can be resolved by the creation of entities or a procedure to keep track of tuples to ensure during operation that there will be one entity that retracts the tuple. Each entity can reside on the same or a remote host or processing device. In a case of remote source, network protocols are used for information exchange and synchronization.
A further aspect of the present invention is illustrated with respect to its application to the call processing environment to solve the feature interaction in call processing and maintenance. The present invention solves the problem of creation of multiple features which may interact with each other. The present invention provides a system and method for the operation of features and the addition of new features to an existing system to provide a viable way to determine if the new feature will undermine the goals of an existing feature. The features are represented by entities. An entity for the feature attempting to do something with a call will place an assertion in the form of a tuple in the tuple space. Examples of such feature assertion entities could be: originating call, terminating call, alerting user, receiving message, sending message, altering data (i.e. proclaiming night service), etc.
These entities assert, using the commands and tuples previously described, requests in the tuple space for permission to proceed with the action. Other features whose entities have registered interest in such occurrences with the call can comment on the proposed action using the commands and tuples previously described. In this, they act as advisors. The originating entity of the assertion can take their interventions and with its own internal logic can decide what would be the best course of action to take.
In this manner, new features can be added, or features upgraded or changed at run time in a call processing system by assertions and responses communicated through the tuple space. Thus, existing features represented by entities, do not need to be directly aware of other or new features beforehand. This provides a flexible way for new features to be added, or existing features customized to the particular requirements.
Coordination of call processing applications with tuple spaces is accomplished by use of the permission/action loop mechanism among features implemented as entities. Each feature entity, when initialized, is informed of the pre-defined sets of command and tuple formats for interacting with the tuple space. For example, a simple call processing service may consist of entities that handle the features of: Originate Call, Originate Call Screening, Terminate Call, and Termination Call Screening. Other features can be implemented in a similar manner to those described herein.
In this example, calls would be originated by the Originate Call feature. When a person or entity, (which may be represented by a agent) decides that it wants to place a call, it places a tuple in the pre-defined form necessary to interact with that tuple space. An example for originating a call is the placement of the tuple into the tuple space to placing a call to 592-2122 such as:
{call_sequence — # 5678:type originate_request:termination_end_point 592-2122}
In the above tuple, the entity is asking if any other feature or entity would like to intervene in the creation of this call. Originate Call feature would have placed a compatible anti- tuple in the tuple space and would therefore receive all comments on its intended actions. It would assess these comments in the mode of the permission/action model and then decide whether to proceed or not.
Origination Call Screening is feature intended to monitor outgoing calls to prevent calls to specified numbers. The entity for the feature would be place an anti-tuple of the form.
{:call_sequence_# ?:type originate_request:termination_end_point ?}
in the tuple space in order to be informed of any outgoing call attempt. The entity for the feature would receive the tuple and match the value of the:termination endpoint ingle with the members of its denial list. If the endpoint is denied, it can place a tuple of the form:
{:call_sequence — # 5678:type originate_request:status prohibit} in the tuple space to indicate its objection.
FIGS. 2 to 8 provide an example of the implementation of the synchronized tuple space of the present invention in a subset of a PBX system used to resolve the feature interaction problem. PBX sub-set 200 illustrates a portion of a PBX system having hundreds of features for illustration purposes only. The invention can be adapted to all of the features. The PBX system of which PBX subset 200 is a part, may be any commercially available PBX such as is well known in the art such as the SX-2000 available from Mitel Corporation. While the invention is described with respect to a PBX system and the subset of such system, the invention is not restricted to such systems or parts of such systems. It is obvious to one skilled in the art that the invention may be adapted to other computing systems, environments and applications. Entities in FIGS. 2 to 8 are implemented as agents. While agents are used for the purposes of the illustration in FIGS. 2 to 8 , it can be appreciated by a person skilled in the art that the invention may be adapted or implemented without the use of agents using other obvious alternate embodiments without deviating from the sphere and scope of the invention. Software agents, may be implemented as software processes written in any appropriate computer language running on a processing device. A general system using agents has been described in the publications “Toward A Taxonomy of Multi-Agent Systems”, Int. J. Man-Machine Studies (1993), 39, 689–704, Academic Y. C. Pan and Jay M. Tenenbaum, Transactions on Systems, Man and Cybernetics, (Vol. 21, No. 6, November/December, 1991, pages 1391–1407. An example of a communication system using agents has also been described in U.S. Pat. No. 5,638,494. Each of the software agents could be implemented using Object Linking and Embedding (OLE) Component Object Model (COM) objects. Both OLE and COM were developed by Microsoft®.
PBX sub-set 200 illustrates three user accounts that have the following features. User account 1 has the feature call forwarding. User account 2 has the features call screening and call forwarding to account 3 when account 2 is busy.
Tuple space content 204 of synchronous tuple space 201 is shown at consecutive time slices 202 for seven consecutive time slices numbered 1 to 7 illustrated in FIGS. 2 to 8 respectively. Read requests 206 , in requests 208 and cancel requests 210 received from any of entities 212 , 214 , 216 , and 218 are also shown at each of the seven consecutive time slices 202 .
The interaction described above is managed as follows: origination entity 212 manages origination of a call on account 1 ; call screening entity 204 manages originating call screening on account 1 ; termination entity 216 manages termination of a call on account 2 ; and forwarding entity 218 manages call forwarding on account 2 . Turning to FIG. 2 , the activities occurring during the first time slice 202 are illustrated. At the start of the first time slice, at operation 230 , call screening entity 214 subscribes to obtain notice of any calls placed by account 1 . At operation 232 , termination entity 216 subscribes to obtain notice of any calls made to account 2 . At operation 234 , forwarding entity 218 subscribes to notice of any calls made to account 2 . At operation 236 , call forwarding entity 218 subscribes to any calls made to account 2 where the status is busy.
Turning to FIG. 3 , the activities occurring during time slice 2 are illustrated. At the start of time slice 2 , at operation 240 , origination entity 212 originates a call by account 1 to account 2 . At the same time, by operation 242 , origination entity 212 subscribes to being given notice of any comments or objections raised by any other entity of the call placed by account 1 to account 2 . At the end of time slice 2 , at operation 244 , call screen entity 214 receives notice of the call to account 2 by account 1 because of the previous read request placed by entity 214 in synchronous tuple space 201 . At operation 246 , termination entity 216 receives notice of the call to account 2 by account 1 because of the previous read request placed by entity 216 in synchronous tuple space 201 . At operation 248 , forwarding entity 218 receives notice of the call place to account 2 by account 1 because of the previous read request on synchronous tuple space 201 by forwarding entity 218 .
Turning to FIG. 4 , at the start of time slice 3 , at operation 250 , in response to the notice received of the call to account 2 by account 1 , termination entity 216 issues an out command notifying all entities of synchronous tuple space 201 that the call by account 1 to account 2 is busy. At the end of time slice 3 , at operation 252 , origination entity 212 , because of the previously issued in command, receives notice that the call from account 1 to account 2 is busy. At operation 254 , forwarding entity 218 , because of the previously issued read command, receives notice that the call from account 1 to account 2 is busy. At operation 256 , the tuple in tuple space 204 by operation 250 is discarded in trash 220 by the in request 208 content.
Turning to FIG. 5 , at the start of time slice 4 , at operation 260 , in response to the notice that the call to account 2 from account 1 is busy, forwarding entity 218 , using the “out” command, places a tuple into tuple space content 204 , indicating that the call to account 2 from account 1 is forwarded to account 3 . At the end of time slice 4 , at operation 262 , origination entity 212 receives notice that the call from account 2 to account 1 has been forwarded to account 3 . At operation 264 , the tuple placed in tuple space 204 by operation 260 is discarded to the trash 220 by the “in” request 208 content.
Turning to FIG. 6 , at the start of time slice 5 , at operation 270 , origination entity 212 issues a “cancel” command canceling the call by account 1 to account 2 . Origination entity 212 , at operation 272 , in response to the previously received notice from forwarding entity 218 , issues an “out” command placing a call by account 1 to account 3 . At the end of time slice 5 , at operation 274 , call screening entity 214 receives notice of the call by account 1 to account 3 . At operation 276 , as a result of the tuple and cancel request 210 , the call by account 1 to account 2 is discarded in trash 220 .
Turning to FIG. 7 , at the start at time slice 6 , at operation 280 , call screening entity 214 issues the “out” command placing a tuple in tuple space content 204 that the call to account 3 from account 1 is prohibited. At the end of time slice 6 , at operation 282 , origination entity 212 receives notice that the call to account 3 from account 1 has been prohibited. By virtue of in request 218 , at operation 284 , the tuple in tuple space 204 is discarded in the trash 220 .
Turning to FIG. 8 , at the start of time slice 7 , at operation 290 , origination entity 212 issues a cancel command placing a tuple in cancel request 210 canceling the call by account 1 to account 3 . At the end of time slice 7 , the tuple space content 204 is discarded at operation 292 into trash 220 .
The tuple space does not accept any new requests until all above is executed. During that time all requests are buffered and processed during next time slice. In this manner, feature interactions can be conveniently, efficiently and effectively managed and resolved.
The present invention can also be used in a contract for service environment.
Turning to FIG. 9 , the application of the present invention in a contract environment with a printing service and a number of print agents is illustrated. Contract environment 300 contains synchronized tuple space 302 . Synchronized tuple space 302 is illustrated with multiple time slices 304 numbered from 1 to 7. For this example, time slices are set at 1 shared increment. Time slices 304 represent segments of time, which may be seconds or parts of seconds and go on infinitely. Synchronized tuple space 302 also has tuple space content 306 , read request 308 and in requests 310 . Environment 300 also has application 312 , print agent 314 and print agent 316 . Various items places in tuple space 302 are, when no longer needed, discarded in trash 318 . At the start of the first time slice 304 , at operation 320 , application 312 issues an out command indicating its request to print a file named of type postscript by 2:00 p.m. Also, to keep track of the status of the print request, application 312 issues in command at operation 322 for the status of any operation relating to the file foo.
At the start of time slice 2 , print agent 314 issues a read command to be put on notice of any request to print any file of any type. At operation 326 , print agent 316 also places a read for requesting notification of any file that is requested to be printed of any type. At the end of the second time slice, at operation 328 , print agent 316 receives notice of the request to print file foo of type postscript by virtue of the print request issued by application 312 . At operation 330 , print agent 314 also receives notification of the print request to print the file foo of type postscript. At the start of time slice 3 , print agent 314 , being the more efficient print agent, issues an out command indicating that it is committing itself to print the file foo. At operation 332 , notice that print agent 314 is received by application 312 that it will commit itself to printing file foo. At operation 336 , by virtue of the in request 310 , the out command is discarded to trash 318 .
Nothing happens at time slice 4 or 5 . At the start of time slice 6 , print agent 316 , being the slower print agent, issues the outcome indicating that it will also commit itself to printing the file foo. At the end of the 6 time slice, at operation 340 , application 312 receives notice that agent 316 has committed itself to print the file foo. At operation 342 , at the end of the 6 time slice, the request which was placed in synchronized tuple space 302 by application 312 at operation 320 has been resident on the tuple space 302 for a duration of 6 time slices and is discarded. At operation 344 , by virtue of in request 310 , the out command issued at operation 338 is discarded in trash 318 . Finally, the in request 310 , issued by application 312 at operation 322 , having existed on tuple space 302 for the preset time of 6 time slices is discarded in trash 318 .
One practical effect of the synchronized tuple space can be illustrated when we consider a case when tuple space operates with time slice 0.5 second, (not shown). Assume that all response times remain the same as for FIG. 9 (that is, agent 2 takes 6 second to respond). If Agent 1 responds within 1 second, its response arrives on the tuple space during time-slice 6 . The response is sent to the application. The response from Agent 2 would arrive at time-slice 13 . But by then there is no request for the job on the tuple space having expired and been discarded. It means that the Application never considers the commitment from Agent 2 and Agent 2 has no chance to get the contract for the print job. We can see that reduction of duration of the time slice excludes slow agents. It would favor faster agents and discriminate against slower ones, but gets the job printed quicker.
In a further embodiment, the invention facilitates the ability to ignore advice (override) for business reasons. Since an entity is in charge of its activity, and is only asking the advice of other entities, it is free to ignore the advice and take action as it deems appropriate. This ability to choose a course of action based on its own internal logic is an important part of this new system and method. An extension of this embodiment is that an entity can request the advice of a human user before taking an override action. The entity, through an appropriate user interface will inform the user of the prohibition and seek advice on whether to override the prohibition. This will allow a user to override the prohibitions enforced by the system if the needs of the business require it. Use of the override feature can easily be collected, recorded, logged and reported by an automatic process to a person or authority for monitoring purposes and to prevent abuse. Use of the override feature can be augmented with a password type mechanism. Thus, for example in a call processing environment, if a user requires to make an important international call for an urgent business need and does not have the class of service to do it, he can override the prohibition generated by the system. The use of a synchronized tuple space and the system and method of the present invention is in contrast to prior art systems where prohibitions and overrides are difficult to program directly into the system with multiple features or entities. The clear division of responsibilities provided by the synchronized tuple space of the present invention provides a straightforward and direct path to simplify the implementation of such override capabilities. This allows the system to adapt using human intelligence to the minute to minute needs of the organization. The inability to do such a thing has been one of the major problems of prior art groupware systems.
According to a further aspect of the present invention, Business Rules can be added to Customize the environment to a Particular Owner. Observers could be added as entities with the ability to query the tuple space to obtain information on the state of the processing environment.
The ability to add observers which can support a new feature allows the addition of business rules which are specific to the enterprise to the system gracefully. If a business requires they say no international calls can be placed during night service, an assertion to this effect can be placed in the tuple space which would enforce this business rule. Those shows that the technique can allow the customization of systems to meet the specific business needs of an owner.
The tuple space allows the coordination of components which act at different speeds. Slow and fast components can communicate through the tuple space using the same mechanisms.
Although the invention has been described in terms of the preferred and several alternate embodiments described herein, those skilled in the art will appreciate other embodiments and modifications which can be made without departing from the sphere and scope of the teachings of the invention. All such modifications are intend to be included within the scope of the claims appended hereto. | 4y
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REFERENCE TO RELATED APPLICATIONS
This disclosure claims the benefit of the filing date of International Application No. PCT/EP00/03872, having an international filing date of Apr. 28, 2000, which designated the United States of America, and this disclosure is the United States national stage of that international application. This disclosure further claims priority to Germany patent application 199 19 880.2, filed Apr. 30, 1999, Germany patent application 199 20 905.7, filed May 6, 1999, and Germany patent application 100 02 401.7, filed Jan. 20, 2000.
FIELD OF THE INVENTION
The invention relates to a process and a device for the attachment of label jackets to products such as bottles.
BACKGROUND OF THE INVENTION
A corresponding machine is known from European Patent No. 0 584 516. This machine has a revolving table, with dishes that are arranged at regular intervals on a common sector of a circle, for the free standing uptake of bottles. On each one of these dishes, a roll of labeling hose, an installation for the separation of label jackets, and a pair of separating jaws that can be lowered and lifted for seizing the separated label jackets and to pull them over a bottle, are arranged in a manner so that they rotate.
The drawbacks of this construction design are the considerable cost and the fact that replacement of the numerous rolls of label hose is time consuming. Because of the free standing bottles, the speed of revolution and thus the production output are considerably limited. Furthermore, on the one hand, the evenness of the height of attachment of the label jackets to a multitude of bottles is unsatisfactory, and, on the other hand, the operating reliability is critical, especially when the external wall of the bottles are wetted with a fluid. These drawbacks are connected with the fact that a label jacket, at the time when the force of friction between the label and the bottle is greater than between the separating jaws and the label, stops the axial relative movement with respect to the bottle and adheres to it. The height of attachment of the individual jacket labels depends on the individual friction conditions and, therefore, it is not exactly defined. Moreover, the operating reliability is problematic when the separating jaws return to their original upper starting position, because there are still bottles on the support dishes.
SUMMARY OF THE INVENTION
The invention is based on the task of providing a process and a device with high fitting precision and operating reliability.
According to the invention, the bottles are seized, before a label jacket is pulled over them, in the area of their mantle surface, until the separating jaw pair which holds a label jacket, coming from above, surrounds, in a manner which is known in itself, at least for a portion of the longitudinal extent of the bottle to be fitted. In the subsequent course of the operation, the holding device for holding the bottles by their mantle surface is temporarily released, and the label jacket is pulled by the separating jaw pair, with simultaneous support of the bottom of the bottle, to the desired final position, where the lowering movement of the separation jacket pair is then stopped, while the label jacket continues to be held at its lower edge with friction lock by the separating jaws. Then the bottle is again seized by a part of its mantle surface which in the meantime has been covered with the label jacket that has been pulled over it, where the label jacket is held by friction lock or pressed against the external side of the bottle. The separating jaw pair releases the hold grip on the forward lower margin of the label jacket only then, and it is then lowered completely under the standing surface of the bottle. During this lowering movement of the separation jaw pair, the label jacket, advantageously, can no longer change its height position on the bottle, so that the position of the label jacket with respect to the bottom of the bottle is maintained uniformly with great precision in the case of a multitude of bottles, that is the height position tolerances of the height of adhesion can be kept in a very small range.
Advantageously, the separation jaw pair is designed in such a manner that its coupling action, with friction lock, is simultaneously applied to the radial internal and the external surface, and, as a result, it is possible to avoid an unnecessary large widening of a label jacket to generate sufficient frictional forces.
Since, in the proposed process, a bottle is supported at all times by its circumference, before, during and after the pull-over application of a label jacket, by an area of its mantle surface, high speeds of rotation can be achieved with an accordingly high production output without tipping of the bottle.
According to an embodiment variant of the invention, the separation jaw pair is lifted into the original upper position, only after the removal transport of the bottles that have been provided with a label jacket from a bottom dead center position, so that, advantageously, no disturbances can be caused by collision with a bottle or jamming of the separation jaws.
A particularly advantageous embodiment is one where the movements in height of the clamp jaw pair for pulling on the label jacket and for the return movement into the starting position is controlled by a cam control, but caused by a working cylinder or another appropriate drive (engine, etc.), because, as a result, the processing times, particularly the return time to the initial position, can be kept shorter than with a pure cam control, because there is no risk of self inhibition. The angle of rotation of the revolving table required for a complete cycle of movement of the clamp jaws is, accordingly, reduced, that is a smaller revolving table diameter is sufficient, with the same output level.
BRIEF DESCRIPTION OF THE DRAWINGS
Below, a preferred embodiment of the invention is explained with reference to the figures. In the drawing:
FIG. 1 a shows a machine with a revolving table for pull-over application of label jackets to bottles in a simplified diagrammatic top view,
FIG. 1 b shows a radial cam assigned to the revolving table for the actuation of gripper clamps provided on the revolving table to hold bottles, as well as star wheels to load and unload the bottles in a top view,
FIGS. 2 a – 2 c show a vertical cross section through the revolving table of FIG. 1 seen in the direction of the arrow A, in different operating positions,
FIGS. 3 a – 3 c show a diagrammatic top view of a separation jaw pair to seize and pull over label jackets in different operating positions, corresponding to the series of FIGS. 2 a – 2 c,
FIG. 4 shows a vertical complete cross section through the revolving table of the machine in FIG. 1 ,
FIG. 5 a shows a partial cross section of FIG. 4 in an enlarged representation,
FIG. 5 b shows a partial cross section corresponding to FIG. 5 a with an additional label jacket support,
FIG. 5 c shows a top view of a label jacket support of FIG. 5 b,
FIG. 6 shows a side view of a separating jaw unit in the viewing direction X in FIG. 5 a,
FIG. 7 shows a top view of a separation jaw unit in the viewing direction Y in FIG. 5 a,
FIG. 8 shows the development view of the radial cams for the movement in height of the separation jaw units,
FIG. 9 shows a top view of a bottle seizing unit at the revolving table of the machine according to FIG. 1 b in two different positions, and
FIG. 10 shows a variation of the machine according to FIG. 1 with two revolving tables in a diagrammatic top view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The machine 1 shown in FIG. 1 a essentially consists of a horizontal table top 2 , on which a revolving table 3 is rotatably secured with rotation about a vertical axis 3 ′, which revolving table is provided with several bottle dishes 4 arranged at regular intervals on a common sector of the circle. With displacement, a feed star wheel 5 , with associated feeding conveyor 7 , and a one-piece endless screw 8 and a delivery star wheel 6 , with associated removal conveyor 9 , are located on the revolving table 3 , with circumferential displacement.
Both the feed start wheel 5 and the delivery star wheel 6 are equipped at their periphery with seizing devices to seize and hold bottles at their mantle surface ( FIG. 1 b ). These gripping devices, for example, with swivel clamp arms which are in opposite direction in pairs, can be controlled at different places of their circumferential path, from a gripping position into a release position. Such clamp star wheels are described in detail, for example, in U.S. Pat. No. 5,607,045.
Above the common transfer point I between the revolving table 3 and the feed star wheel 5 , a cutting block 10 is provided on a cross bar 13 , where the cutting block is held in fixed position, for the feeding, unfolding of a film hose and for cutting off label jackets E, where the label film hose 11 is pulled off a hose reservoir 12 which is secured laterally to the machine, and, in the process, it is led to the cutting block 10 over several deflection rollers. The above mentioned cross bar 13 can be adjusted, in its height, for adaptation to different label jacket lengths, advantageously by an electromotor adjustment device, which is not shown in detail. The cutting block 10 can be constructed according to the Published German Patent Application DE 2950785 A1.
The revolving table 3 , the star wheels 5 and 6 , the conveyors 7 and 9 , as well as the one-piece endless screw 8 are driven continuously with synchronous speed and positioning with respect to each other, in a circular movement, by individual motor drives or a common machine drive and drive elements. The cutting block 10 has drive devices to effect, synchronously with respect to the movement of the revolving table, the advance, with exact positioning, of the label jacket hose and the cutting off of label jackets E by the cutting tool of the block 10 . Reference is made to the above mentioned German Patent Application concerning the exact construction.
The construction of the revolving table 3 is explained in greater detail below with reference to the vertical cross sectional representation shown in FIGS. 4 and 5 a . The base of the revolving table 3 is formed by a horizontal support disk 30 , which is secured, so as not to allow rotation, at its center to a vertical main shaft 31 , and which bears, on its top side, the bottle dish 4 (not shown in the left half of FIG. 4 ). Each bottle dish 4 is associated with a pair of parallel guide rods 32 in a vertical position on the top side of the carrier disk 30 , which pair is located radially inside the imaginary sector of a circle, on which the bottle dishes 4 are arranged. The ends of the guide rods 32 which are turned away from the carrier disk 30 , and turned upward, bear a ring disk 33 , whose middle is empty, and which is arranged parallel to the support disk 30 , on which ring disk several double-action pneumatic cylinders 34 are secured in a vertical upright position, in each case in the middle between a pair of guide rods 32 , with associated control valves 60 . To guarantee a stable hold of the cylinders 34 , the vertical upward housing ends of these cylinders are connected by a second ring disk 35 , which also has an empty middle. The piston rod 36 of the double-action pneumatic cylinders 34 can be moved out, vertically and in parallel, between a pair of guide rods 32 where, in the first ring disk 33 , a hole is present in each case in a position in the middle between the guide rods 32 , to allow the free penetration of the piston rods 36 .
The downward pointing end of the piston rod 36 is secured to slide block 37 which preferably has two parallel bore holes, each of which is penetrated by a guide rod 32 , which slide block, on its backside turned toward the main shaft 31 , presents an upper and lower guide roller 38 or 39 . The guide rollers 38 and 39 are, in each case, rotatably secured to swiveling levers 38 b and 39 b ( FIG. 6 ), which in turn are secured to slide blocks 37 . In the swiveling range of these levers, shock absorbers 38 c and 39 c , respectively, with terminal abutments are attached to the slide block.
The top guide roller 38 is applied against the control surface of an upper, cylindrically bent, radial cam 40 , which is attached to the circumference of a horizontal disk 42 . This disk 42 has a pipe-like attachment, which is secured with pivot bearings to the top end of the main shaft 31 . At the bottom side of the disk 42 , there are several separator bolts 44 , which hang downward, and which are displaced at regular intervals over the circumference. At the lower ends of the separator bolts, a circular disk 43 , with empty middle, is attached, which carries at its circumference a bottom radial cam 41 for the other guide rollers 39 , with central attachment. In addition, the bottom radial cam 41 is held in a position so it cannot rotate by a clamp piece 45 provided on the separator bolts 44 . The bottom radial cam 41 , which is also cylindrically shaped, has a control surface pointed upward, on which the guide rollers 39 move.
The course of the curves of the two radial cams 40 and 41 can be seen in detail in the development view represented in FIG. 8 , where the running direction of the guide rollers 38 , 39 is directed, starting from the 0 degree mark (see also FIG. 1 b ), in the direction of the arrow from the right to the left. In order to be able to use the machine 1 to process different bottle types and/or jacket labels E, where the adhesion height, that is the lower margin of the label jacket with reference to the bottom of the bottle, can be different, the lower radial cam 41 has a curve section 41 b (see FIG. 8 ) whose height can be adjusted continuously, and whose control surface determines the adhesion height of the label jacket E on the bottles F. This curve section 41 b is connected in each case with two slide bushes 48 which are led in a manner so they can slide on two separated separator bolts 44 and which can be lifted or lowered, continuously, by means of a threaded spindle which is not shown ( FIG. 4 ).
In order to prevent the radial cams 40 and 41 from also turning, an angular torque support 46 is attached to the top side of the disk 42 , which support is braced by a stationary column 47 arranged; outside of the revolving table 3 , vertically on the table top 2 .
The bottom dishes 4 which are arranged on a common circle sector of the support disk 30 at a fixed height, and which in each case are surrounded by a centering ring 14 secured by a spring method, whose coaxial height can be moved, and which presents a margin which surrounds and holds the bottle dish 4 , and extends above it, and which is adapted to the contour of the bottom of the bottle. This centering ring 14 is coupled with a rod 15 which is led in a manner so it can be shifted in the support disk 30 , which projects with its lower end over the bottom side of the support disk 30 and supports a guide roller 17 ( FIG. 5 a ). Below the support disk 30 , at the circumferential path of the guide rollers 17 , a radial cam 18 is attached in a manner so it cannot be turned on the table top 2 , which, in the circumferential area from the delivery star wheel 6 to the feed star wheel 5 effects a lowering of the guide rollers 17 against the return force of a coil spring 16 with permanent vertical upward action. In this process, the upper margin of the centering ring 14 is held, during the feeding and delivery of the bottles F on the bottle dishes 4 , under the top side of the bottle dishes ( FIG. 2 c ).
In addition, each bottle dish 4 is associated with two shafts 19 a , 19 b , which are arranged at an interval, parallel and vertically with respect to each other, with rotatable securing in the carrier disk 30 . Each of these shafts supports at its top end a horizontal grip arm 20 a and 20 b , respectively, which extends outward and which is secured in a manner so it can not be turned, which arms together form controllable grip pincers 20 for seizing and holding a bottle F to be labeled on a bottle dish 4 ( FIG. 9 ). At the lower end of the shaft 19 a , a lever 21 a fitted with a elongate hole 22 is attached, and at the lower end of the shaft 19 b , a lever 21 b equipped with a vertical bearing bolt 23 is attached, in a manner so they can not turn. The bearing bolt carries a sliding block 24 which can be swiveled and which penetrates into the elongate hole 22 , and a guide roller 25 with displaced height, which roll is applied to the radial external control surface of a curve ring 26 which is maintained on the table top 2 in a manner so it can not turn. At the two levers 21 a , 21 b , a tension spring 27 is applied, which is permanently active in the direction of a closing movement of the gripper clamp 20 . The form of the curve ring 26 which has two cam sections which project radially outward can be seen in FIG. 1 b . When passing this section, the guide roller 25 is pressed outward, where the grip arms 20 a , 20 b swivel outward in opposite directions. The different positions of a gripper clamp 20 can be seen in FIG. 9 . Holding of the bottle can occur at two places of its mantle surface with separation intervals in the axial direction, and alternately controlling the two axially displaced holding devices to rise, during the pull-over application of the label jacket, in such a manner that the object is at all times subject to or guided by at least one holding device.
FIG. 7 shows the construction of a spreading jaw unit 50 for the friction-positive seizing and pulling over of a label jacket E on the trunk of a bottle F, for example, a PET bottle. It consists of two internal jaws 51 a , 51 b and the counter arms 52 a , 52 b associated with them. The internal jaws each have a horizontal application surface 53 for the lower margin of a label jacket and a half-shell 54 which is bent upward, and whose curvature is adapted to the bottle diameter. The following half-shell, in the direction of rotation of the revolving table 3 , can have a lower height than the preceding half-shell. The counter arms, which are also curved, each carry two elastic rubber resilient pads 55 which can be applied radially from the outside to the half-shell, and which can be regulated to achieve a uniform seizing of a label jacket. On a support plate 56 which is inserted horizontally and can be quickly exchanged on the slide block 37 , two vertical bearing bolts 57 for the internal jaws and two additional vertical bearing bolts 58 for the counter arms are attached, where the bearing bolts 58 freely penetrate two curved elongate holes 59 in the internal jaws. In each case, a hinge 66 is used to couple the counter arms with their corresponding internal jaw, in such a manner that the swiveling of the internal jaws toward each other results in the swiveling of the counter arms away from each other, and vice versa. Close to the half-shells, one of these attracting tension springs 61 engages with the internal jaw. Approximately in the middle between the bearing bolts 58 , a control cam 68 which can not be turned is located on a shaft 62 is secured horizontally in the slide block 37 , where the height of the control cam is between the internal jaws. At the opposite end of the same shaft, a control segment 67 which presents a total of three guide rollers 63 , 64 , 65 , is secured in a manner so it can not turn. With the two guide rollers 63 , 64 which are arranged on the side of the control segment turned away from the slide block, the symmetrically shaped control cam can, as desired, be adjusted by rotation in the clockwise direction or in the opposite direction by approximately 90° by means of curve section 70 arranged at the circumferential path, while the third guide roller 65 , located on the opposite side of the control segment, is used to maintain the label holding position of the spreading jaw unit 50 , while its downward movement is used for the pull-over application on a bottle. For this purpose, this guide roller 65 is associated with a vertical longitudinal guidance strip 71 , which rotates with the revolving table 3 , and where the guide roller runs along this guidance strip during the lowering.
In contrast to the above described embodiment, the counter arms, if appropriately shaped—as shown in FIG. 1 b —can each be secured with one end rigidly to the diametrically opposite internal jaw.
The course of the operation during the passage of a bottle through the machine is described below, essentially with reference to FIG. 1 a:
A bottle F which arrives on the conveyor 7 is seized by the one-piece endless screw 8 , introduced in an appropriate position into the feed star wheel 5 , seized by the latter's controlled clamps and positioned at the common contact point I on a bottle dish 4 of the revolving table 3 , where, at the same time, the centering ring 14 is led upward and the associated gripper clamp 20 is closed. The corresponding clamp of the feed star wheel instantaneously releases the bottle.
At the same time, a spreading jaw unit 50 which is associated with the bottle approaches the cutting block 10 as a result of its upward movement, where the half-shells 54 and the rubber resilient pad 55 are separated from each other at this time. At the same time, the label hose 11 is advanced from above downward, and a label jacket E is cut off, which is then located, with its lower margin, on the application surface 53 of the internal jaws 51 a , 51 b , that is the half-shells are located within the label jacket and the rubber resilient pad outside. In order to prevent the tipping of the label jacket at the time of the uptake and acceleration in the direction of rotation of the revolving table 3 , a concave curved support shell 49 is located at the height of the label jacket E which has just been separated from the hose, which shell moves in the same direction as the revolving table—seen in the direction of rotation—and is applied to the back side of the label, where the support shell 49 is secured with fixed height at the radial external margin of the ring disk 33 by means of a bracket ( FIG. 5 b ). FIG. 5 c shows the shape of the support shell 49 in a top view.
Immediately thereafter, the shaft 62 with its control cam 68 is rotated in such a manner that the half-shells 54 are swiveled away from each other and at the same time the rubber resilient pads 55 are swiveled inward and in opposite directions, until the label jacket is clamped at its lower margin, outside and inside, with friction lock. In the case of a stretchable jacket, the latter is expanded in the process to an extent which is larger than the diameter of the bottle.
When passing through sector II ( FIG. 1 a ), the label jacket is pulled, by the separation jaw unit 50 which is pressed downward by the pneumatic cylinder 34 , from top to bottom over a bottle F. As soon as the spreading jaw unit, during the lowering movement, approaches the gripper clamp 20 which holds the bottle, the gripper clamp is opened for a short time, long enough so that the spreading jaws are able to pass through the gripper clamp (second half in sector II). Later, the gripper clamp 20 can again be closed, to such an extent that the bottle is led by its circumference, but a sufficient slit remains to continue pulling through the label jacket. As soon as the label jacket has reached the intended adhesion height, the lifting movement of the spreading jaws is stopped, the gripper clamp 20 is completely closed (label pressed against the bottle trunk) and the half-shells 54 are swiveled slightly inward (the clamping of the lower label margin is released). These processes occur in sector III.
Even before the delivery star wheel 6 is reached, the spreading jaw unit 50 is now again lowered, until the half-shells are located completely under the bottle dishes 4 ( FIG. 2 c ). In the case of a shrink wrap jacket, “which has an internal diameter equal to or larger than the external diameter of the bottle,” the preliminary shrinking (hot air, etc.) for affixing the label can now occur at the revolving table 3 . In addition, the centering ring 14 is lowered now, and the gripper clamp 20 is opened, when the delivery star wheel 6 has seized the bottle for transfer to the conveyor 9 .
Then, the pneumatic cylinder 34 is adjusted for lifting, so that the spreading jaw unit 50 again reaches its original upper position before passing the feed star wheel 5 (sector IV).
During the entire treatment process, the bottles are transported without change in height position through the machine.
FIG. 10 represents a machine variant for high outputs, which is formed by a mirrored arrangement of two individual machines according to FIG. 1 a or 1 b , that is this double machine has two feed star wheels 5 and 5 ′, two carousels or revolving tables 3 and 3 ′, as well as two delivery star wheels 6 and 6 ′, but only one common conveyor 7 , one removing conveyor 9 and the one-piece endless screw 8 . The star wheels 5 , 5 ′ or 6 , 6 ′, respectively, which are opposite each other and which can be driven in opposite directions to each other, in each case contact the sector of a circle of their counter part and they are equipped, at the circumference, with controllable clamps—according to the representation in FIG. 1 b —which can be adjusted selectively from a seize position for seizing a bottle into a release position, and vice versa, by means of switch cams, not shown, which are arranged in a fixed position at certain places of their circumferential path. This partition measure, that is the interval between two adjacent bottle dishes 4 on the two revolving tables 3 and 3 ′, is twice that of the partition measure of the feed and delivery star wheels 5 , 5 ′ and 6 , 6 ′. All the bottles which are supplied continuously in a single track by the feed conveyor 7 are pulled apart by the one-piece endless screw 8 to the partition measure of the feed star wheel 5 and seized by the latter. At the common contact point of the two feed star wheels 5 and 5 ′ each second bottle F is released by the first feed star wheel 5 and simultaneously seized by the second feed star wheel 5 ′. In this manner, the bottles F and F′ are alternately led to the two revolving tables 3 and 3 ′. Each revolving table is associated in the transfer area of its feed star wheel with a cutting block 10 or 10 ′ for the separation of label jackets E from a label film hose. On the side of the delivery, the finished, labeled, bottles F and F′, which arrive alternately from the two revolving tables 3 and 3 ′ at the common contact point of the two delivery star wheels 6 and 6 ′, are again combined to one row and they are transferred from the delivery star wheel 6 ′ to the removal conveyor 9 . As a result of this modular construction, a larger range of outputs can be covered than with only two variants. It is understood that, instead of clamp star wheels, it is also possible to use alternate solutions with differently designed holding devices for the selective seizing of the bottles, such as, for example, vacuum star wheels or similar transport installations. | 4y
|
[0001] This application is a continuation of Patent Cooperation Treaty Application PCT/EP2012/074694, filed Dec. 6, 2012, which in turn claims priority from Great Britain Patent Application 1120972.3, filed Dec. 6, 2011, both of which are incorporated herein by reference in their entireties.
TECHNICAL FIELD
[0002] The present invention relates to three-phase metering of fluid flows, for example at wellheads, where it is necessary to measure the individual flow rates of oil, water and gas fractions within the fluid flow out of an oil well.
BACKGROUND ART
[0003] Knowledge of the individual flow rates of the gas fraction, the oil fraction, and the water fraction within the flow of fluid from an oil well is an important part of the efficient management of the well and the associated subsurface reservoir. Such wells typically tap into reservoirs such as that shown in FIG. 1 , in which a simplified well is shown penetrating a reservoir. The reservoir consists of a permeable rock formation typically filled with a lower layer of water 110 , an intermediate layer of oil 112 , and an upper layer of gas 114 trapped under a layer of cap rock 116 . The result of this is that the balance between the fractions of each that are extracted is affected by the positioning of the well perforations 120 at the lower end of the production string 122 relative to the layers, and the flow rate of the fluid out of the well. The flow rate is relevant in that over production of a well can reduce the total amount of oil recovered due to a number of reasons, including drawing the underlying water layer 124 up towards the perforations 120 and creating a cone of water above the undisturbed oil/water contact in the region of the well. The appropriate response to this is to reduce the overall flow rate in order to optimize the oil extraction rate. Typically this is achieved with a choke valve 134 located in or close to the wellhead 132 . The choke value may be variable, but more commonly it consists of a fixed orifice of a precise flow section that under normal operating conditions, produces “critical flow”, a supersonic flow that is only dependent on the wellhead pressure upstream of the choke, independent of the pressure downstream of the choke. Selecting a specific size of choke enables the reservoir engineer to select an optimum flowrate for the well. Within a reasonably wide range, the well flowrate is then not affected by varying back pressure in the flowline 130 to the surface facility 126 .
[0004] The surface facility separates the oil, water and gas streams and measures the flowrate of each phase, disposes of the water (and sometimes gas), and passes the other fluids to market. The surface facility typically receives the flow from many wells, and has a test separator and a production separator. Most of the wells are comingled and flow into the production separator, where only the aggregate flowrates are available, From time to time, the flow from each well is sent to the test separator, and then the phase flowrates for oil, gas and water for that well are measured. It will be clear that for most of the time, the well flows are not measured; instead flows are inferred from general measurements by a process known in the industry as “allocation”. Allocation is important as the reservoir and well production can only be optimized if the flow from each well is known. Also, in certain countries, royalty rates for each state are calculated on the basis of well production within the state boundaries, so a general production figure for an entire oil field that crosses state boundaries is not detailed enough, and individual well production figures are needed.
[0005] Individual separators for each well would be very costly, and so there is a need for a multiphase flowmeter (MPFM) that is cost effective for individual wells. A further advantage of installing MPFMs on each well is that rather than having individual flowlines running back to the surface facility, it is possible to comingle the flows of wells into a single larger flowline back to the facility. This approach has considerable cost advantages, particularly for subsea wells.
[0006] Attention has therefore been directed to in-line flowmeters able to distinguish between the three fractions. An example can be seen in U.S. Pat. No. 5,461,930 which discusses the measurement of two- and three-phase fluid flow. Volumetric and momentum (mass) flow meters are provided, which yield corresponding data from which (and from knowledge of the respective densities), the relative flow rates of the different phases can be determined.
[0007] Another example can be seen in US2004/0182172A1, which uses Venturis and chokes in the flowline to create pressure differentials along the flowline. The gas fraction is very much more compressible than the oil and water fractions, and therefore from assessing the pressure differentials produced by several different chokes and/or Venturis, it is possible (in principle) to determine the gas fraction. The relative water & oil fractions can then be determined by electrical properties of the fluid, particularly its capacitive properties in a manner that is acknowledged by US2004/0182172A1 as being known in the oil & gas industries.
[0008] This arrangement is proposed as an in-line meter 128 ( FIG. 1 ) for use in the flowline 130 at some intermediate point between the production well and a remote processing location. However, as discussed in U.S. Pat. No. 5,461,930 in relation to still earlier designs, it suffers from the inherent difficulty that in order to create significant pressure differentials, there must be a significant flow restriction (by way of either a choke or a venturi). Thus, the flow of the fluid out of the well and to the remote processing location may be adversely affected. If the meter is designed so that there is little effect on flow, then the pressure differentials are correspondingly reduced and the accuracy of the meter is affected. Typically, such a device will have to measure pressure differentials of 1 or 2 bar in a base pressure of about 100 bar. To determine the proportions of the different fractions, three pressure differentials need to be compared, meaning that in order to obtain accurate information as to the fractional ratios, the pressure differentials will need to be accurate to millibar levels. This is a significant challenge.
SUMMARY
[0009] Embodiments of the present invention are directed to provide a multi-phase flow meter that can operate accurately without having an adverse effect on the fluid flow out of the well (or other context in which it is installed) and along the flowline.
[0010] Embodiments therefore provide a multi-phase flow meter, including a flow conduit leading from an inlet to an outlet and comprising a variable inlet restriction, a variable outlet restriction, a pressure sensor and a volumetric flow meter, located between the variable inlet restriction and the variable outlet restriction, the flow meter further comprising a controller adapted to receive data from the pressure sensor and the volumetric flow meter, and to adjust the variable inlet restriction and the variable outlet restriction in accordance with at least one program, wherein the at least one program causes the controller to adjust one of the variable inlet restriction and the variable outlet restriction such that the fluid pressure between them adopts a first pressure, then further adjust the restriction such that the fluid pressure between the restrictions adopts a second and different pressure, and to record the first pressure, the second pressure, and the volumetric fluid flow rates at the first pressure and at the second pressure, whilst adjusting the other of the variable inlet restriction and the variable outlet restriction so that the total flow restriction imposed by the two restrictions is maintained at a substantially constant level.
[0011] The variable inlet and outlet restrictions can be continuously variable between a minimum restriction and a maximum restriction, ideally monotonically so. Ideally, when at the maximum restriction, all flow is prevented. This allows maximum flexibility of the device. Alternatively, variable inlet or outlet restriction could be variable between a plurality of discrete values, which may provide the necessary degree of freedom at lower cost or complexity. Such an arrangement could be, for example, an on-off valve in parallel with a bypass path containing a flow restriction. The volumetric flow meter can be an ultrasonic flow meter or a turbine flow meter, for example.
[0012] We prefer that the controller has a further program, in addition to the program mentioned above, which causes the controller to close fully the inlet or the outlet flow restriction and to open fully the outlet or the inlet flow restriction, respectively, to maintain this state for a period of time, and to adjust the calibration of at least one of the pressure sensor and the volumetric flow meter during this period.
[0013] Thus, a multi-phase flow meter according to the invention can be summarized as being one that includes a flow conduit in which is located a variable inlet restriction, a variable outlet restriction, and a control arrangement adapted to vary the restrictions in concert so as to control the pressures in surrounding flowlines while varying the pressure in the flow conduit between the restrictions, further comprising a pressure sensor and a flow meter located between the variable inlet restriction and the variable outlet restriction for measuring the varying pressure and the resulting flow rates.
[0014] The above allows the calculation of the relative proportions of gas and liquid phases in the fluid that is flowing through the device, as will be explained below. Thus, the multiphase flow meter of the invention preferably further comprises a computing means to calculate the relative fractions of gas and liquid flowing through the flow conduit, based on the measured pressures and flow rates.
[0015] The multi-phase flow meter can also comprise a mass flow meter located between the inlet and the outlet flow restrictions. With knowledge of the proportion of liquid in the fluid flow, and of the relative densities of the liquids that are flowing, this then allows the computing means to calculate the relative fractions of different liquids, based on the measured volumetric and mass flow rates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows the general layout of a known oilfield extraction system.
[0017] FIG. 2 shows a vertical sectional view through a multiphase flowmeter according to the present invention.
[0018] FIG. 3 shows the multiphase flowmeter of FIG. 2 with the downstream valve closed.
[0019] FIG. 4 shows the multiphase flowmeter of FIG. 2 with the upstream valve closed.
[0020] FIG. 5 shows a pressure/time curve for the pressure inside the multiphase flowmeter of FIG. 1 .
DETAILED DESCRIPTION
[0021] The present invention achieves its desired aim by integrating the functions of the flow meter 128 and the choke 132 . In a “live” well (i.e. one not requiring pumping in order to lift the oil to the surface) the oil/water/gas mixture will leave the well at a pressure dictated by the properties of the reservoir that the well is tapping into, the reduction of pressure due to the hydraulic pressure head of the fluids in the well, and frictional losses, and may be in the region of 1,000 psi. This needs to be reduced for the flowline to about 300 psi or less, which is usually achieved by way of a choke 132 ( FIG. 1 ). This is simply a flow restriction that serves to reduce the pressure of the fluid released from the well 108 to the flowline 130 to a level that is sufficient to ensure adequate flow and yet low enough to avoid damage.
[0022] FIG. 2 shows a multiphase flowmeter (MPFM) 1 according to the present invention. It includes a fluid inlet 2 , and fluid outlet 3 connected by a suitably pressure-rated conduit. The fluid flow within the MPFM 1 from the inlet 2 to the outlet 3 is controlled by an inlet valve and an outlet valve. The inlet valve consists of an inlet actuator 6 that controls an inlet valve stem 5 , and an inlet valve seat 4 towards and away from which the inlet actuator 6 can move the inlet valve stem 5 so as to impose a variable flow restriction, The outlet valve likewise consists of outlet actuator 9 , outlet valve stem 8 and outlet valve seat 7 , acting in a like fashion. The inlet valve and the outlet valve are both continuously and precisely variable from closed to fully open, controlled by the PFM controller (not shown). The valves are monotonic, so that at all points of their movement, a small opening movement of the valve stem will cause a small decrease in flow resistance. All sensor information (to be described below) is also sent to the MPFM controller.
[0023] Combined pressure/temperature sensors, 10 , 11 , 12 , 13 , 14 and 15 monitor the pressure and temperature of the fluid in the various parts of the flowmeter from the inlet 2 to the outlet 3 . Generally, there is a combined pressure/temperature sensor after each flow-affecting element within the MPFM 1 so that the fluid flow can be monitored throughout the device. This enables remote diagnostics of developing problems, such as scaling, wax or sand contamination within the various sections.
[0024] Fluid entering via the fluid inlet 2 thus passes through inlet valve seat 4 and its pressure may be reduced to a greater or lesser extent depending on the position of the inlet valve. This is followed by fluid mixer 16 , intended to mix the fractions within the fluid flow in order to create a homogenous mixture. Such fluid often separates when allowed to flow freely, into gaseous fractions at the top (etc.) and the fluid mixer 16 comprises a series of baffles and vanes aimed at preventing this. This is followed by a series of sequential flow straighteners 17 , 19 , 22 which aim to establish or restore axial flow in the fluid. The fluid then exits the MPFM 1 through outlet valve seat 7 to the fluid outlet 3 , with its pressure again being reduced to a greater or lesser extent depending on the position of the outlet valve.
[0025] The pressure and temperature change across the inlet valve can be obtained by the difference between sensors 10 and 11 , the pressure and temperature change across the fluid mixer 16 can be obtained by the difference between sensors 11 and 12 and the pressure and temperature change across the outlet valve can be obtained from by the difference between sensors 14 and 15 .
[0026] The pressure and temperature change across the inlet valve, along with the precise position of the inlet valve may be used to monitor and quantify the stability of flow into the device over time. This can be achieved if the MPFM controller has knowledge of the relationship between the inlet valve position and the flow resistance of the valve at that position. This information, along with the pressure drop across the inlet valve, enables an approximate gross flowrate to be calculated. This gross flowrate can be used to check the other flowrates calculated at various points in the meter and at various stages during the measurement process. Significant errors or discrepancies might indicate an error or fault condition, while small discrepancies can be used to provide correction factors.
[0027] The region of the flowmeter 1 between the straighteners 17 and 19 has a homogenous axial flow. The fluid velocity in this region is determined by an ultrasonic flowmeter 18 . This will typically be a Doppler meter of known construction, although time-of-flight or correlation instruments may also be used. The pressure/temperature sensor 13 measures the pressure and temperature of the fluid in this region, which is at the heart of the measurement system. Between straighteners 19 and 22 , the fluid passes through an orifice plate 20 , across which the differential pressure is measured by differential pressure sensor 21 .
[0028] In the preferred embodiment, where the flowmeter is used for accurately measuring 3-phase flow (oil, water, gas) from a production well 108 , the well 108 providing the source of the fluid will typically be fitted with standard safety equipment such as a subsurface shut-in valve and surface shut in valves. The well production fluid is then routed to the inlet 2 of the MPFM 1 , will flow through the MPFM 1 , and out of the outlet 3 , which is connected to a surface flowline 130 leading to a remote processing facility 126 . It will be noted that pressure/temperature sensor 10 will now read the wellhead pressure, and pressure/temperature sensor 15 will now read the flowline pressure at the wellhead end of the flowline 130 .
[0029] It should be noted that MPFM 1 performs the function of the traditional fixed “choke valve” 132 in regulating the well production flowrate, as well as measuring the 3-phase flow, so the choke may be removed, or alternatively set to a size that limits the well to the highest safe rate. In routine use the MPFM controller is commanded to maintain a certain flow resistance equivalent to a certain size of traditional choke valve as required for the optimum production of the well. It should be noted that the MPFM controller may achieve this by setting the inlet valve fully open, and the outlet valve to the required flow resistance. Alternatively, the MPFM controller could achieve the same overall effect by setting the outlet valve fully open, and setting the inlet valve to the required flow resistance. Furthermore, the MPFM controller can smoothly change the valves from the first combination to the second combination by gradually closing the inlet valve and opening the outlet valve in such a way that the flow resistance of the valve combination remains unchanged during the transition. During this time, the pressure in the MPFM between the inlet valve and the outlet valve will smoothly change from the inlet pressure (wellhead pressure) to the outlet pressure (flowline pressure). As the total flow resistance of the MPFM is constant during this transition, the well flow will be substantially constant, the wellhead pressure will remain constant and the flowline pressure will remain constant. Only the pressure inside the MPFM will change.
[0030] In this way, the MPFM 1 of FIG. 2 (comprising two variable choke valves) is able to establish a flow restriction equivalent to a traditional choke valve 132 , while establishing any desired fluid pressure in the flow path between the two variable choke valves. So far as the flowline 130 is concerned, the situation is identical to a single choke valve 132 as shown in FIG. 1 . However, the MPFM controller is able to manipulate the pressure within the MPFM 1 to any desired level falling between the wellhead pressure and the flowline pressure.
[0031] The MPFM 1 may also be used to shut the well in. FIG. 3 shows the outlet valve closed, and the inlet valve fully open. In this configuration, pressure/temperature sensors 10 , 11 , 12 , 13 , 14 will all be reading the same pressure as there is no flow through the MPFM. This pressure will be wellhead pressure. FIG. 4 also shows a fully shut-in well, but this time the inlet valve is closed and the outlet valve is fully open. In this case, pressure/temperature sensors 11 , 12 , 13 , 14 , 15 will all read the same pressure, which will be the flowline pressure (with no flow in the flowline). It is important to note that in these cases, the pressure sensors can be auto zeroed/auto calibrated, a process where differential offset errors are eliminated by comparing readings when all sensors are known to be exposed to the same pressure. In this case, the ability to set a low pressure (the flowline pressure) and a high pressure (the wellhead pressure) enables both zero and gain auto alignment to be performed, thus adjusting the calibration as necessary. In practice, this allows differential pressures to be adequately measured with a pair of absolute pressure sensors rather than an additional differential sensor in most parts of the MPFM.
[0032] Referring again to FIG. 2 , under normal operation, when the MPFM is controlling at the optimum well flowrate, the inlet valve and the outlet valve are preferably set at a similar flow resistance. This central setting provides half the total pressure drop across each valve, and hence equalizes and minimizes erosion of the valves. To perform a measurement cycle, the MPFM controller gradually opens the outlet valve and closes the inlet valve in a smooth transition to a setting which establishes a lower pressure in the MPFM 1 , which is then held. A set of measurements are then taken (see below). The MPFM controller then gradually returns the inlet and outlet valve to the central setting which is then held, and another set of measurements are taken. In this way, a set of measurements are taken at two pressures. The flow through the MPFM all the time remains constant, because the MPFM controller is maintaining a constant flow resistance for the overall MPFM during the measurement cycle. It is possible to confirm that the flowrate has not changed during a measurement cycle by monitoring the pressure drop across the inlet valve with respect to the inlet valve position as described above. A complete set of measurements thus consists of:
Pressure P from pressure/temperature sensor 13 Temperature T from pressure/temperatures sensor 13 , Fluid velocity V from ultrasonic flowmeter 18 Differential pressure DP from differential pressure sensor 21
There are thus two sets of measurements from the same sensors, designated
Central measurement set; PI, Tl, VI, DP 1 Lower measurement set: P 2 , T 2 , V 2 , DP 1
The calculations to be carried out are therefore as follows, based on the following parameters:
[0000]
Measured Parameter
At PI
At P2
Units
Fluid velocity
Fv1
Fv2
m/s
Pressure
P1
P2
psia
Temperature
T1
T2
C.
Differential Pressure
DP1
DP2
psid
[0039] In addition, certain parameters need to be calculated in a straightforward manner, i.e.;
[0040] Volumetric flow rate at P 1 , Q 1 =Fv 1 ·ax (ax being the conduit cross-sectional area)
[0041] Volumetric flow rate at P 2 , Q 2 =Fv 2 ·ax
[0042] For the purposes of describing the system, we define P 2 as being the lower of the two pressures, P 1 and P 2 . Assuming that the mass flowrate is constant, the volumetric flow rate at P 2 will therefore be greater than at P 1 .
[0043] The increase in the volumetric flowrate is therefore Qd=Q 2 −Q 1 .
[0044] For the purpose of illustration and clarity, it is assumed in these calculations that liquids are incompressible, that the gas fraction behaves as a perfect gas, and the reduction in volume of crude oil when gas is released is negligible. Those skilled in the art will be aware of how such second order corrections may be applied in order to reflect the actual fluid properties.
[0045] For a perfect gas,
[0000] p 1· v 1/ t 1= p 2· v 2/ t 2 (1
[0046] v 1 =k·v 2 , where k=p 2 ·t 1 /(p 1 ·t 2 )
[0047] v 1 =kE/(1−k), where expansion factor, E=v 2 −v 1 -- (1
[0000] Considering one second of flow (so we can equate volumes and flowrates), we can write:
[0048] Volumetric flowrate of gas fraction at P 1 , Qg 1 =k·Qd/(1−k)
[0000] Hence the liquid volumetric flowrate at P 1 , QL 1 =Q 1 −Qg 1
[0049] The densities of the gas, oil and water fractions at different temperatures and pressures are measured when a reservoir is first produced, and then updated from time to time. This process, known as PVT analysis, is well known. From PVT analysis, the density of the oil and water fractions, Do, Dw are stored in the MPFM controller, and the exact gas density at P 1 and P 2 , Dg 1 and Dg 2 is calculated, using the perfect gas equation from the gas density at standard pressure and temperature.
[0050] The gas mass flow rate Mg 1 =Dg 1 ·Qg 1
[0051] The volumetric liquid fraction, FL 1 =QL 1 /Q 1
[0052] The volumetric gas fraction, Fg 1 =1−FL 1
[0053] The total fluid density can be obtained from the differential pressure across the orifice plate.
[0000] D 1=2 ·C 2 ·A 2 ·DP 1/ Q 1 2
[0054] where A is the cross section area of the orifice hole,
[0000]
C
=
C
d
1
-
β
4
,
[0055] β=d 2 /d 1 ,
[0056] d 2 =diameter of the orifice hole,
[0057] d 1 =diameter of the conduit, and
[0058] C d is the discharge coefficient, typically of the order of 0.6
[0000] The density of the liquid fraction DL 1 can now be calculated from the equation:
[0000] D 1= Dg 1 ·Fg 1 +DL 1 ·FL 1
[0059] where D 1 , Dg 1 , Fg 1 and FL 1 are now known.
[0060] Finally, the oil fraction, Fo 1 , can be calculated from the equation:
[0000] FL 1 ·DL 1 =Do·Fo 1 +Dw ( FL 1 −Fo 1)
[0061] where FL 1 , DL 1 , Do, Dw are known.
[0000] And the water fraction is given by Fw 1 =FL 1 −Fo 1 .
[0062] Now that fractions and the volumetric flow rates for all three phases have been computed, the mass flow rates for each phase can be computed as the phase densities are known. Hence a total mass flow rate can be computed.
[0063] The entire procedure above can then be repeated, reducing all the results to the P 2 environment.
[0064] Comparing results between the P 1 environment and the P 2 environment, clearly the fractions and volumetric flowrates will differ, due to the different pressures. However, the mass flowrates should be the same. In particular, the total mass flowrate computed should be the same for the two sets of computations.
[0065] The sensitivity of the computation to instrumentation errors from the absolute sensors (P and T) are largely eliminated in the above computation, due to the invention allowing the same pressure and temperature sensor to be used in both P 1 and P 2 measurement sets.
[0066] The calculations are still sensitive to errors in the fluid velocity, Fv 1 and Fv 2 , and the differential pressure, DP 1 and DP 2 . These errors can largely be eliminated via a normalization method. In this method, a correction velocity is speculatively added to Fv 1 (for example), and the two calculation sets are computed, and the two total mass flowrates calculated are compared. The process is then repeated, using the Newton-Raphson method adjusting the correction velocity until the two computed mass flowrates are the identical. This process dramatically increases the accuracy of the calculated volumetric fractions and velocities. Other parameter could be corrected in a similar manner, and other correction methods will be apparent to those skilled in the art.
[0067] FIG. 5 shows a possible pressure/time profile for the apparatus. The pressure shown is of course the pressure within the measurement region, i.e. between the inlet and outlet valves 6 , 9 as will be sensed by the sensors 11 , 12 , 13 , 14 . The pressure prior to the inlet valve and the pressure subsequent to the outlet valve 9 are of course dictated by the combined flow resistance imposed by the two valves 6 , 9 collectively, and are controlled to remain within the desired limits by adjustment of that collective flow resistance. The balance between the flow resistance imposed by the inlet valve and that imposed by the outlet valve 9 can be varied, and this allows the pressure in the fluid between them to be adjusted as desired between the upper and lower pressures either side of the device.
[0068] Thus, the default state is one in which the pressure 50 within the device is approximately midway between the higher pressure 52 at which the fluid arrives from the well, and the lower pressure 54 in the flowline 130 after the multiphase flowmeter. As mentioned, this places both the inlet and the outlet valves at an approximate midway position in which wear is minimized.
[0069] When a measurement is to be taken, the pressure, temperature, and flow rate readings can be taken. Then, the inlet valve 6 can closed slightly and the outlet valve 9 opened slightly, causing the pressure within the device to drop to the reduced level 56 . A second set of pressure, temperature and flow measurements can be taken. The inlet and outlet valves can then be returned to their previous positions and the default state 58 will be resumed.
[0070] If desired, the pressure can then be set at a higher value 60 in a corresponding manner, to provide a third set of pressure, temperature and flow values. These can be used to check the results calculated from the first set and provide a confidence level for the results. Once this is done, the pressure can then be returned to the default value 62 where it will remain until the next measurement cycle 64 . Further confirmatory measurements could be taken at the same pressures or at different pressures, as desired.
[0071] Of course, the pressure could be raised instead of being increased as shown and as described above. Where multiple pressure readings are taken, these could be taken in any desired order.
[0072] In a context where there is plenty of excess pressure, the well could be designed with a conventional choke valve to drop the pressure, followed by the MPFM operating between a reduced upper pressure and the desired flowline pressure. Such as arrangement still has the advantages of significantly lower instrumentation cost, and also benefits from the other advantages set out above. Alternatively, the valves 6 , 9 could be replaced with on/off valves, each in combination with a fixed choke valve in parallel with the respective on/off valve. In such an arrangement, there would always be flow through the meter, which would operate over a narrow pressure range. It could comprise a simplified (and therefore reduced cost) valve set due to the lower pressures. The on/off valves can be simple ball valves, which could be connected together on a single shaft driven by one actuator. If the ball valves are placed 90 degrees out of phase, so either one or the other is on, while the other is off, then this will enable quite rapid toggling between the two pressures, allowing the system to react quickly if the flowrate is trending quickly. Indeed, such a device could toggle pressures as frequently as every second.
[0073] The invention can also be used with a Coriolis-type meter, arranged between the inlet valve and the outlet valve, A coriolis meter measures both massflow and density. In the manner described above, the invention derives both P 1 (and T 1 ) and P 2 (and T 2 ), and the density at pressures P 1 and P 2 gives the gas fraction, from which it is possible to extract the fluid density, and hence the oil/water fractions (assuming that the individual oil and water densities are known. This leaves one redundant reading, i.e. the mass flow at P 1 and at P 2 . As we know these are the same, they can be used to normalize the results.
[0074] Other momentum flowmeter devices can be used in substitution for the orifice plate, such as a venturi or cone. The system is flexible as to its design and could be re-engineered to a physical arrangement suited to use on the surface, or in a subsea context, or in a downhole location.
[0075] The above-described system could of course be deployed in an alternative context (i.e. other than that of hydrocarbon extraction) where it was desired to measure the relative fractions in a multi-phase fluid flowing through a conduit. The high-speed variant mentioned above could be particularly appropriate for such use.
[0076] Embodiments of the invention may be implemented in part in any conventional computer programming language such as VHDL, SystemC, Verilog, ASM, etc. Alternative embodiments of the invention may be implemented as pre-programmed hardware elements, other related components, or as a combination of hardware and software components.
[0077] Embodiments can be implemented in part as a computer program product for use with a computer system. Such implementation may include a series of computer instructions fixed either on a tangible medium, such as a computer readable medium (e.g., a diskette, CD-ROM, ROM, or fixed disk) or transmittable to a computer system, via a modem or other interface device, such as a communications adapter connected to a network over a medium. The medium may be either a tangible medium (e.g., optical or analog communications lines) or a medium implemented with wireless techniques (e.g., microwave, infrared or other transmission techniques). The series of computer instructions embodies all or part of the functionality previously described herein with respect to the system. Those skilled in the art should appreciate that such computer instructions can be written in a number of programming languages for use with many computer architectures or operating systems. Furthermore, such instructions may be stored in any memory device, such as semiconductor, magnetic, optical or other memory devices, and may be transmitted using any communications technology, such as optical, infrared, microwave, or other transmission technologies. It is expected that such a computer program product may be distributed as a removable medium with accompanying printed or electronic documentation (e.g., shrink wrapped software), preloaded with a computer system (e.g., on system ROM or fixed disk), or distributed from a server or electronic bulletin board over the network (e.g., the Internet or World Wide Web). Of course, some embodiments of the invention may be implemented as a combination of both software (e.g., a computer program product) and hardware. Still other embodiments of the invention are implemented as entirely hardware, or entirely software (e.g., a computer program product).
[0078] Although various exemplary embodiments of the invention have been disclosed, it should be apparent to those skilled in the art that various changes and modifications can be made which will achieve some of the advantages of the invention without departing from the true scope of the invention. | 4y
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This is a division of application Ser. No. 736,142, filed May 20, 1985.
BACKGROUND OF THE INVENTION
1. Field Of The Invention
This invention relates to exercise apparatus having locking means to facilitate positioning of an adjustable member in a desired position.
2. Description Of The Prior Art
In connection with exercise apparatus of various types it has been known to provide means whereby translational or rotational movement of a component may be effected after which the component may be locked in a desired position. Such movements are frequently necessary or desirable as a result of users of different sizes and physical characteristics needing to have different dimensional relationships with the apparatus. Such adjustments are frequently desirable not merely as a matter of comfort, but also in order to facilitate improved safety and efficient use of the equipment.
In exercise apparatus such as stationary bicycles, for example, it will frequently be necessary or desirable to adjust the elevation of the seat which supports the user, the elevation of the handlebars which are engaged by the user as well as other portions of the apparatus.
While numerous means have been suggested for use in this context, there remains a need for improved locking devices for use in this environment.
SUMMARY OF THE INVENTION
The present invention has met the above described need by providing an exercise apparatus and associated locking means for securing at least one adjustable member in a desired position. A tubular portion of the exercise apparatus receives a portion of the locking means which is threadedly connected to an external operating knob. Rotation of the operating knob in a first direction establishes compression in the locking means portion disposed within the tubular portion thereby effecting locking of the adjustable member in the desired position.
In one embodiment, a unitary frame-like locking member has the adjustable member passing therethrough and cooperates with recesses in the wall of the tubular portion of the exercise apparatus. In effecting locking, the knob is rotated in a first direction so as to place the frame-like locking member in compression and thereby lock the adjustable member in the desired position.
In another preferred embodiment, a pair of tubular members have associated cooperating recesses which when the knob means are rotated in a first direction will establish compression in the two tubular members to thereby lock the adjustment member in the desired position.
These and other objects of the invention will be more fully understood from the following description of the invention on reference to the illustrations appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a form of exercise bicycle employing locking devices of the present invention.
FIG. 2 is a partially exploded, partially in section schematic illustration of a first embodiment of locking means of the present invention.
FIG. 3 is a cross-sectional illustration showing the apparatus of FIG. 2 in locked position.
FIG. 4 is a cross-sectional illustration showing the apparatus of FIG. 2 in unlocked position.
FIG. 5 is an exploded partially schematic deal of another embodiment of the locking means of the present invention.
FIG. 6 is a cross-sectional illustration showing the embodiment of FIG. 5 in locked position.
FIG. 7 is a cross-sectional illustration showing the embodiment of FIG. 5 in unlocked position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring again to FIG. 1, there is shown an exercise bicycle which has a body portion 2, a pair of pedals 4, 5, longitudinal base support 6, a pair of transverse base supports 7, 8 and a seat 12 which is supported by adjustable member 14 whose position is locked by locking means 16 of the present invention. Adjustment member 14 is received within tubular member 15 which in turn cooperates with locking means 16. Adjustable member 21 is received within tubular member 20 having opening 22 and in turn cooperates with locking means 18. Locking means 18 secures adjustment member 21 in the desired angular position within opening 22 and locking means 24 secures handlebars 26, 28 and housing 2a in the desired axial position on adjustable member 21. The housing 21 which in the form shown is movable with handlebars 28, 29 on adjustable member 21 and may contain electronics and display means to show speed, distance, calories used and the like. In this manner, by adjusting locking means 16, 18 and 24 the elevation of seat 12, the elevation of handlebars 26, 28 and the rotational position of handlebars 26, 28 may be established.
Referring to FIGS. 2 through 4, a preferred embodiment of the present invention will be considered. A tubular portion 30 of the apparatus which will receive an adjustable member 56 is provided with an opening so that the locking means may be provided. The locking means in this embodiment consists of a frame-like member 32 which defines an opening 36 within which adjustable member 56 may be reciprocated when the locking means is in unlocked position. Fixedly secured to the locking member 32 is a threaded stud 38 which projects through the opening in the tubular portion 30 and is threadedly engaged within hub portion 42 of knob 40. It will be appreciated that as the knob is rotated in a first direction the framing member 32 will be urged responsively in a path oriented generally transversely with respect to the longitudinal axis of the adjustable member 56. The apparatus is such that movement in a first direction will establish locking of the adjustable member 56 in a desired position and the rotation of the knob 40 in the other direction will unlock the adjustable member 56. The adjustable member 56 will be received within the passageway 44 of the tubular member 30.
As is shown, the tubular portion 30, in the preferred embodiment has a pair of generally opposed recesses 52, 54. In the locked position, such as is shown in FIG. 3, the framing member 32 will be received in the recess 54 disposed adjacent to knob 40. When it is desired to unlock the adjustable member for moving it to another position or rotating the same, the knob 40 is rotated in the opposite direction thereby causing translational movement of the framing member 32 in a path generally transverse to the longitudinal axis of adjustment member 56 and relieving the compressive restraint thereby permitting free movement of the adjustment member 56.
It will be appreciated that this device permits effective secure locking of the adjustable member which may directly or indirectly be secured to a seat, handlebars or other portions of exercise apparatus desired to be moved while permitting manual operation in an easy manner.
While the embodiment of FIGS. 2 through 4 illustrate a generally rectangular frame member 32 associated with a generally rectangular tubular member 30 it will be appreciated that the members 30, 32 may be of generally circular configuration or any other desired configurations. One advantage of having a non-circular configuration is that undesired rotation of the frame member 32 with respect to the tubular member 30 is resisted.
Referring further to FIGS. 5 through 7 a further embodiment of the invention will be considered. In this embodiment, a first tubular locking member 66 is provided with a pair of relieved surfaces 68, 72 which define, respectively, recesses 70, 74. Connecting means 78 are fixedly secured to the tubular element 66 and, in the form shown, are of generally U-shape having a pair of lateral walls 80, 84 and a base wall 82. A threaded stud 86 is fixedly secured to the base wall 82 and projects outwardly therefrom. In use, the tubular element 66 and the connecting member 78 would be disposed within a tubular portion such as portion 30 in FIG. 2 with the stud 86 projecting through an opening in the tubular portion. A second tubular element 92 would also be positioned within the tubular portion 30. This member also has a pair of surfaces 94 (second surface not shown) which define recesses 96 (second recess not shown). This structure has a closed end wall 98 having an aperture 100 through which stud 86 passes. Knob 102 is threadedly secured to stud 86. The four recesses (two opposed pairs) in the two tubular elements 66, 92 are adapted, when in closed position and placed in compression to effect clamping engagement with the adjustable member 104. FIG. 6 shows the structure in compressed condition locking the adjustable member 104 and FIG. 7 shows the structure in unlocked position which permits rotational and translational movement of adjustable member 104.
While the devices of the present invention may have locking components made of any suitable material, it is presently preferred to make them of a suitable metal or resinous plastic.
While several preferred geometric configurations have been illustrated for purposes of clarity of disclosure, it will be appreciated that the invention is not so limited. A prime feature of the invention is that the construction be such that rotation of an externally disposed knob which is threadedly secured to a framing component results in the framing elements disposed within the tubular member being placed in compression so as to lock the adjustable member which has a path of movement generally transverse thereto in secure position.
While for convenience of reference herein specific reference has been made to exercise bicycles it will be appreciated by those skilled in the art that the apparatus of the present invention may be employed in a wide variety of types of exercise equipment such as rowing machines, fitness treadmills and pogo sticks, for example.
Whereas particular embodiments of the invention have been described above for purposes of illustration, it will be appreciated by those skilled in the art that numerous variations of the details may be made without departing from the invention as described in the appended claims. | 4y
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TECHNICAL FIELD
This invention relates to pistons for internal combustion engines particularly of the two stroke cycle high output diesel type. More specifically, the invention relates to a high strength oil cooled floating piston member having integral crown supporting gussets and cooling ribs with modifications for improving cooling in the combustion bowl rim radius without adversely affecting engine combustion efficiency.
BACKGROUND
The development of pistons for a well known series of two cycle diesel engines manufactured for use in railway locomotives and other applications has extended over many years. Continuing modifications in the engine design, involving among other things higher power output per cylinder, have created increasingly severe operating requirements of pressure and temperature which have from time to time required modifications in piston design to maintain the record of extended durability desired. Considerable background information about the history and development of pistons for engines of this type is found in U.S. Pat. No. 3,240,193 issued Mar. 15, 1966, corresponding Canadian patent No. 771,421 issued Nov. 14, 1967 and Canadian patent No. 963,752 issued Mar. 4, 1975, all assigned to the assignees of the present invention.
A prior piston design, shown in the Canadian No. 963,752 patent provided an oil cooled floating piston construction having a thin walled crown including a recessed combustion bowl surrounded by a rim defining a squish land. The rim portion of the crown was connected with a cylindrical wall including an annular heat dam of limited cross section, a ring belt and a side thrust absorbing cylindrical skirt portion.
The prior piston design provided rigidity in the crown and ring belt structure through use of a plurality of thin radially extending nonperforate gussets connecting an internal thrust collar directly with the interior bowl and rim portions of the piston crown and the heat dam and ring belt portions of the skirt-defining cylindrical wall. Additional cooling fins provided between gussets in the rim and heat dam area joined with the gusset structure to carry heat from the connected surfaces of the piston rim and combustion bowl for transmission to cooling oil directed against the interior wall surfaces of the piston to maintain adequate cooling of the piston walls.
In conjunction with continuing engine improvements accompanied by a further increase in cylinder power output and a resultant increase in thermal loading on the pistons, it was determined that even greater cooling effectiveness should be provided in the piston crown at the location of the annular arcuately curved wall, or radius, at the inner edge of the crown rim which joins the surrounding planar squish land with the outer portions of the recessed combustion bowl. This "rim radius" portion of the piston is generally the hottest area in the crown of a direct injection diesel engine piston utilizing a symmetrical fuel spray pattern. This is partly because the fuel spray pattern and the combustion bowl configuration direct the major portion of combustion into the outer reaches of the combustion chamber. Then downward motion of the piston during the power stroke results in a high speed turbulent flow of extremely hot gas outward over the rim to fill the space between the piston squish land and the cylinder head as the piston moves away from the head which defines the cylinder closed end. Added to this is the relative difficulty of cooling a salient corner of the piston crown wall which has a much greater surface area exposed on the hot combustion chamber side than is exposed to coolant in the piston undercrown. In short, the rim radius lies in an area of high heat input to the piston and, due to the piston geometry, it is difficult to cool.
If the temperature of a piston becomes excessive during operation at maximum power settings of an engine, the interior surface may become hot enough to partially oxidize the cooling oil and create carbon deposits on the interior surfaces in the high temperature crown rim. The carbon layer built up thereby reduces the effectiveness of oil cooling and further raises the rim surface temperature. This may result in physical and metallurgical effects which eventually produce surface cracking in the area of the hot rim radius and may result in limiting the life of the piston.
SUMMARY OF THE INVENTION
The present invention provides solutions to the piston rim radius cooling problem by increasing convective and conductive heat transfer from the rim area in order to minimize the formation of undercrown carbon deposit layers and to mitigate the effects of any layer which may form. Among the results of the inventive designs employed to accomplish these purposes are the provision of increased interior cooling surface area relative to the exterior area provided by increasing the rim radius and adding interior fins. In addition, selective increases are provided in the undercrown thickness leading away from the rim radius to conduct additional heat away from the rim. Moreover a change in the exterior configuration at the rim radius, involving an angular break or discontinuity in the curvature at its juncture with the squish land, is provided to recapture a loss in turbulence related engine performance occasioned by increasing the rim radius.
These and other features and advantages of the invention will be more fully understood from the following description of certain preferred embodiments taken together with the accompanying drawings.
BRIEF DRAWING DESCRIPTION
In the drawings:
FIG. 1 is a cross-sectional view of a two piece piston assembly embodying the invention and including a hollow piston member rotatably mounted on a thrust load receiving carrier;
FIG. 2 is a partial transverse cross-sectional view of the hollow piston member as seen from the planes indicated by the line 2--2 of FIG. 1 viewed in the direction of the arrows;
FIG. 3 is a fragmentary cross-sectional view of the assembly of FIGS. 1 and 2 from the plane indicated by the line 3--3 of FIG. 2;
FIG. 4 is an enlarged fragmentary view of a portion of the hollow piston member of FIG. 1 provided to illustrate more clearly certain features of the invention, and
FIGS. 5 through 8 are cross-sectional views of types corresponding respectively to those of FIGS. 1 through 4 but illustrating a modified piston arrangement incorporating additional features of the present invention.
DETAILED DESCRIPTION
Referring first to FIGS. 1 through 4 of the drawings, numeral 10 generally indicates a two piece piston assembly particularly intended for use in a turbocharged two cycle direct injection internal combustion engine of the compression ignition (diesel) type. Assembly 10 includes a substantially hollow outer piston member 12 which is supported to freely float (rotate) on an inner piston carrier 14. The carrier is in turn pivotally connected by a trunnion pin 16 to the upper end of a connecting rod 18.
The piston and carrier members 12, 14 form a chamber 20 therebetween which is normally supplied with piston cooling oil through a passage not shown, extending upwardly through the carrier. In an assembled engine, the lower end of this passage is aligned to receive a jet of cooling oil emanating from a suitable nozzle or orifice connected in known manner with an oil distribution manifold, not shown, that extends longitudinally of the engine crankcase. Drain means not shown in the carrier allow the return of excess oil to the engine supply sump, thus providing a continuous flow.
The hollow piston 12 is closed at its upper end to form a thin-walled crown or head portion 24. A cylindrical wall portion 26 extends longitudinally from this closed end portion 24. The head of the piston is recessed to form an open semi-turbulent toroidal combustion chamber bowl 28. This bowl has a shallow conical bottom wall 30 which extends radially outwardly from a depending central puller boss 32. A threaded bore 34 is provided in the boss for engagement by a suitable pulling tool.
The edge of the bowl 28 is formed by a curved side wall 36, the upper edge of which is connected to a short radial wall portion 37 by a radiused or arcuate curved annular wall which is commonly known as the rim radius 38. This radius, together with the radial wall portion 37 define a hollow peripheral rim 39 for the piston crown surrounding the recessed combustion bowl 28. The radial wall portion 37 itself includes a planar outer surface or squish land 40 extending from the outer diameter of the piston inwardly to the rim radius. The squish land 40 coacts with an opposing cylinder head, not shown, which defines the end of the combustion chamber, to squeeze out portions of the charge during the upstroke of the piston and create a rapid inflow or squish of gases into the toroidal combustion bowl that causes substantial combustion-promoting turbulence.
The outer edge of the rim 39 connects with the upper end of the cylindrical wall portion 26 of the piston which comprises a heat dam 41 formed as a relatively thin short annular portion of the cylindrical wall. Below the heat dam is a thickened ring mounting portion, or ring belt 42, which is outwardly grooved to receive four longitudinally spaced compression rings, not shown. The purpose of the heat dam 41 is to restrict the conduction of heat from the piston combustion bowl and rim to the ring belt section 42 so as to prevent the piston rings from being exposed to excessive temperatures.
Below the ring belt 42 there is a thinner cylindrical skirt 44 which extends longitudinally downward terminating at its lower end in a thickened portion 46 on which there is formed internally an annular thrust surface 48 for the lower edge of the carrier 14. Below the thrust surface, piston skirt 44 is externally grooved at 50 to receive a pair of oil control rings not shown. A snap ring 52 is received in an internal groove 54 of portion 46 for the purpose of retaining the piston 12 and the piston carrier 14 in assembly.
The interior structure of the piston 12 includes an annular thrust collar 56. This collar is supported longitudinally and coaxially of the piston head 24 and extends normally of the common longitudinal axis of the piston and carrier. The collar 56 is spaced within the lower edge of the ring belt 42 and is concentrically embraced thereby. The central opening through the collar is finished to form a cylindrical bearing surface 58 while the lower surface of the collar is likewise finished to form an annular bearing surface 60. Cylindrical surface 58 is engaged by a mating journal surface formed on a boss 62 centrally disposed at the upper end of the carrier. A separate thrust washer 64 is disposed around the boss 62 and between the annular surface 60 of the piston thrust collar and a mating bearing surface 66 on the upper end of the carrier 14.
The annular thrust collar 56 is structurally connected with the piston bowl and rim, comprising the piston crown, and with the heat dam and ring belt portions of the cylindrical skirt wall by a plurality of integrally formed alternately and equiangularly disposed radially and longitudinally extending imperforate planar gussets 68, 70. Gussets 68 extend upward from the inner edge of the annular collar, being arched inwardly very slightly with a small radius at their juncture with the combustion bowl wall 30. Gussets 70 are angled inwardly from a point above the inner edge of the collar member and extend to radiused connection with the combustion bowl wall, terminating adjacent the central bowl boss 32 so that the inner portion of the combustion bowl wall is supported by these gussets.
Gussets 68, 70 divide the upper portion of chamber 20 in the hollow piston 12 into a plurality of wedge shaped spaces 72. The spaces 72 are open at their inner edges to a central section 74 and are connected to the lower portion of chamber 20 through their lower edges which are open between the thrust collar 56 and the ring belt 42.
Within spaces 72 and equally spaced intermediate the gussets 68, 70, a plurality of shallow cooling ribs 76 are disposed in the hollow rim portion of the piston. These ribs connect the outer surface of the piston bowl with the inner surface of the cylindrical wall upper end defined by the heat dam at the upper end of the ring belt. Ribs 76 like the gussets 68, 70 are thin in cross section so as to act as cooling fins which carry the heat away from the combustion bowl and piston rim surfaces and distribute it to the cooling oil without acting as paths for the excessive transmission of heat from the combustion bowl directly to the piston ring belt.
In operation, the reciprocating action of the piston assembly causes the cooling oil supplied to the chamber 20 to be agitated in a cocktail shaker fashion up and down over the surfaces of the piston walls, the gussets and the cooling ribs so as to perform a scrubbing action which effectively carries away heat from the inner walls of the combustion bowl and rim as well as from the heat dam and ring areas, maintaining their operating temperatures at reasonable levels.
The foregoing portion of the description has described those aspects of the present invention which are essentially like those of the prior art piston arrangement shown in the previously mentioned Canadian patent No. 963,752, the disclosure of which is incorporated herein by reference. The embodiment of FIGS. 1-4 was modified from the prior arrangement of Canadian patent No. 963,752 in the following manner.
The rim radius 38 was first increased 50% to provide a more moderate curvature of the arcuately curved wall joining the squish land 40 with the side wall 36 of the combustion bowl 28. To maintain the original rim thickness in the improved design, an equivalent dimensional increase in the interior radius was also made. To maintain the squish land width equal to that of the previous piston design, the combustion bowl was revised to a configuration somewhat deeper and of smaller diameter.
The increased rim radius had the desired effect of providing a substantial increase in the relative cooling area available on the interior of the rim radius portions of the piston wall as compared to the heat receiving portions of the wall on the outer surface in the rim radius. Accordingly, substantially improved cooling of the hot rim radius was provided. However, the operating result was a small, but significant, loss of fuel efficiency which apparently resulted from reduced turbulence caused by the increase in the rim radius. One theory charged the loss to a Coanda effect which, due to the more moderate rim radius, caused more of the squish gases to follow the contour of the bowl wall with a resulting decrease in the amount of turbulence.
After consideration of a number of alternatives, a modification was made which restored the fuel efficiency loss without decreasing the cooling effectiveness of the modified piston structure. This was accomplished by moving the center of the rim radius slightly closer to the top of the piston so that the outer surface of the radius no longer lay tangent with the planar outer surface forming the squish land. Instead the rim radius intersects the squish land with a sharp edge or angular break 77 defining an angle α (shown in FIG. 4) which in the presently preferred embodiment, equals about 27°. At present, it is considered preferable that the angle α have a value within the range from 25° to 30°. However a smaller angle α of 20° may be adequate to provide a performance improving effect. The physical results of this change included not only the provision of the angular break in the rim curvature where it intersects the squish land but also an increase in the width of the squish land itself, so that it is not at present clear whether the improved fuel efficiency stems primarily from the Coanda effect opposing characteristics of the angular break or from the additional squish effectiveness of the wider squish land.
In physically comparing the improved piston rim and bowl configuration with that of the prior design, the following dimensional characteristics are believed significant. The combustion bowl rim radius at the outer surface was increased from about 4.2% of the piston diameter to about 6.2% of the piston diameter and from 5.7% of the previous bowl diameter to about 8.4% of the new slightly smaller bowl diameter. With related changes in the inner rim radius, the minimum wall thickness at the rim radius was maintained essentially constant but the ratio of the outer to inner surface areas s o /s i was reduced from about 2.4 to less than 1.7 in the new design. This could decrease the temperature difference across the wall over 40% for the same heat flow. Also the width of the squish land was increased from about 7.8% of the piston diameter in the previous design to about 10.2% of the piston diameter in the new preferred embodiment. Comparatively, in the previous embodiment, the width of the planar portion defining the squish land equalled about 10% of the piston bowl diameter while, in the revised preferred embodiment, the wider squish land equals about 14% of the new slightly smaller combustion bowl diameter. It should be recognized that these figures are nominal and subject to substantial variation due to drawing and manufacturing tolerances. However, the tendencies indicated by these changes are nevertheless significant.
Turning now to FIGS. 5-8 of the drawings, there is shown an alternative embodiment of piston assembly including a hollow piston member incorporating the previously described features of the present invention as well as certain additional features. Since the construction of the assembly and the piston member illustrated in FIGS. 5-8 is largely identical to that of the construction of FIGS. 1-4, like reference numerals have been used for like elements or parts, the construction of which will be understood from the description of the embodiment of FIGS. 1-4 which will not be repeated. Instead the embodiment of FIGS. 5-8 will be described by reference to its differences from the first described embodiment, utilizing primed numerals for modified elements or parts.
In the FIGS. 5-8 embodiment, the thickness of the crown bowl wall is varied beginning with a thin cross section equal to the previous embodiment at the rim radius where maximum cooling is desired. The wall thickness is then increased down the bowl periphery toward the thickest portion at the bottom of the bowl, which is directly supported by the radial gussets 68', 70. The wall thickness then is reduced inwardly toward the central puller boss 32 at which point it again has the thickness provided in the embodiment of FIG. 1. The thickened toroidal central portion of the bowl wall is provided to draw heat from the peripheral bowl portions, particularly the rim radius but also from the central portions of the bowl, toward the intermediate annular portion for delivery to the cooling oil and to the supporting gussets which provide additional cooling surface that is directly cooled by the cooling oil. This thickened wall construction is, however, similar to that used for a similar purpose in the piston construction illustrated in the previously mentioned U.S. Pat. No. 3,240,193, the disclosure of which is hereby incorporated by reference.
Another difference in the alternative embodiment is the provision of perforate gussets 68' lying between and, in the present embodiment, alternating with the imperforate gussets 70, which are similar to those of the previously described embodiment. The perforate gussets 68' differ from those of the previous embodiment in the provision of openings 78 adjacent the cylindrical wall, the rim and outer portions of the combustion chamber bowl. These openings separate the perforate gussets 68' from these portions of the piston wall, leaving the perforate gussets connected only to the intermediate, or lower, portions of the piston bowl and to the cylindrical wall at the lower portions of the ring belt.
The purpose of providing these openings 78 in the gussets 68' is to permit the casting of additional thinner ribs 76' which are preferably equally spaced circumferentially between the imperforate gussets 70. The construction is such that, with ten equally spaced imperforate gussets 70 which are found in both illustrated embodiments of the piston, the openings in the perforate gussets 68' allow the provision of 5 cooling ribs 76' in the space between adjacent imperforate gussets. This compares with the arrangement of FIGS. 1-4 in which limitations of the casting process permit only 2 cooling ribs and 1 imperforate gusset 68 to occupy the same space where 5 cooling ribs are located in the embodiment of FIGS. 5-8. The purpose of the additional cooling ribs is, of course, to provide additional undercrown surface for conducting heat from the piston rim, including the radius, to the cooling oil to provide even better cooling of this difficult to cool zone.
While it is recognized that the use of rim cooling ribs separate from the crown supporting structure of a piston is not in itself new, it is believed that the present invention provides a novel combination of piston crown support structure which combines the advantageous effects of the structurally stiff imperforate gusset construction provided by the multiple gussets 70 with the increasing cooling provided by a greater number of cooling ribs as permitted by the openings in the alternate perforate gussets 68' spaced intermediate the imperforate gussets to aid in further stiffening and structurally supporting the piston crown structure while providing additional paths for heat flow from the crown to the piston cooling oil. In addition, the improvements provided in pistons having the embodiment of FIGS. 5-8 are combined with the larger radius rim curvature and the combustionimproving angular break of the previously described piston embodiment to yield a construction having even more improved cooling in the critical rim area while maintaining the necessary structural rigidity to maintain durability in extended operation under high load conditions.
While the invention has been disclosed by reference to certain embodiments selected for purposes of illustration, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments but that it have the full scope permitted by the language of the following claims. | 4y
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to filters for the removal of particulate material from diesel engine exhaust streams, and more particularly to porous ceramic diesel exhaust filters of honeycomb configuration offering improved resistance to thermal shock and other damage under conditions encountered in diesel engine exhaust systems.
[0002] Ceramic honeycomb particulate filters or traps have proven to be extremely efficient at removing carbon soot from the exhaust of diesel engines. Such filters are generally of so-called wall-flow design in that the soot is separated from the engine exhaust stream by capture on the porous channel walls of a honeycomb filter body as the exhaust gases are forced through the porous ceramic walls separating an array of filter inlet channels from an adjacently interspersed array of filter outlet channels. Wall-flow filters can be designed to provide for nearly complete filtration of soot without significantly hindering the exhaust flow.
[0003] In the normal course of using such a filter in the manner described, a layer of soot collects on the surfaces of the filter inlet channels. The reduced wall permeability caused by the presence of this soot layer increases the pressure drop across the filter and thus increases back pressure in the engine exhaust system. This causes the engine to work harder and adversely affects engine operating efficiency.
[0004] This soot-induced pressure drop periodically increases to a point where regeneration of the filter becomes necessary. Regeneration typically involves heating the filter to initiate the combustion and removal by oxidation of the carbon soot layer. Desirably this regeneration is accomplished under controlled conditions of engine management involving a slow burn of the soot deposits over a period of several minutes. The temperature in the filter during such regeneration can rise from about 400-600° C. to a maximum of about 800-1000° C.
[0005] Under certain circumstances, however, a so-called “uncontrolled regeneration” can occur, wherein soot combustion is initiated coincidentally with or immediately preceding a period of engine idle at low exhaust gas flows and relatively oxygen-rich conditions. In that case the combustion of the soot may produce large temperature gradients and temperature spikes much higher than 1000° C., which can thermally shock and crack, or even melt, the filter.
[0006] In addition to capturing the carbon soot, the filter also traps metal oxide “ash” particles that are carried by the exhaust gas. These particles are not combustible and, therefore, are not removed during regeneration. If temperatures during an uncontrolled regeneration are sufficiently high, the ash can sinter to the filter and/or react with the filter to initiate partial melting.
[0007] In view of these circumstances the development of filter designs and engine control systems that can better manage the regeneration cycle and improve the resistance of these ceramic exhaust filters to thermal regeneration damage continues to be a major focus of diesel engine exhaust system engineering effort.
SUMMARY OF THE INVENTION
[0008] The present invention provides ceramic wall flow filter designs offering significantly improved resistance to thermal shock damage arising from uncontrolled filter regeneration and other adverse conditions of use. Also provided are improved processes for diesel engine exhaust emissions control enabled by the use of such filter designs.
[0009] The filters of the invention are particularly well adapted to address the problem of filter cracking or other damage due to high radial temperature gradients that can arise across the diameter of the filter. While somewhat dependent upon the particular exhaust system design being employed, it is found that substantially higher operating and regeneration temperatures are typically reached in filter volumes disposed on and adjacent to the longitudinal filter axis, i.e., the central axis of the filter running parallel with the inlet and outlet channels of the honeycomb structure. Since the peripheral sections of the filter are generally better cooled than axial filter sections, the radial temperature gradient from the filter central axis to the filter outer skin can be particularly large and problematic.
[0010] In accordance with the invention the magnitude of radial temperature gradients arising within such filters is reduced by one or a combination of filter design features. In one approach the heat capacity of axial sections of the filter is increased, relative to that of peripheral filter sections. This can be accomplished, for example, by increasing the thickness and/or changing the composition of the channel walls within the axial section of the filter. A second approach is to modify the channels walls of the filter to reduce exhaust gas flow through the axial section of the filter. Measures such as reducing wall porosity or increasing wall thickness in axial filter portions are effective for this purpose. The result of these measures is that the quantity of combustible soot present in those sections is reduced, and the quantity of soot present in peripheral filter sections relatively increased, in comparison with the quantities present in conventional filters of otherwise similar design operated under similar conditions.
[0011] Including one or both of these features in the filter design can substantially reduce temperature spikes in uncontrolled filter regenerations. In addition, radial temperature gradients during controlled regenerations are smaller. Accordingly, these filters are generally more resistant to thermal damage such as cracking, ash sintering and melting under normal as well as adverse operating conditions.
[0012] In a first aspect, therefore, the invention includes a ceramic honeycomb wall-flow filter conventionally comprising an array of parallel channels separated by porous channel walls running parallel with the central axis of the filter in a gas flow direction from a gas inlet end to a gas outlet end of the filter. The channel array includes a plurality of inlet channels closed at the gas outlet end separated by the porous channel walls from a plurality of outlet channels closed at the gas inlet end, such that exhaust gases entering the inlet channels must pass through the channel walls into the outlet channels prior to discharge form the filter outlet, and such that soot and other particulates present in the gas stream are trapped on or within the channel walls.
[0013] For the purpose of improved thermal durability, the channel walls of an axial group of inlet and outlet channels in the filter of the invention are made to differ from the channels walls of a peripheral group of inlet and outlet channels disposed about the axial group of channels. More particularly the axial group of inlet and outlet channels will comprise channels walls of higher heat capacity and/or higher gas flow resistance than the channels walls within the peripheral group of channels.
[0014] In a second aspect the invention includes an exhaust system for removing particulates from a diesel engine exhaust stream employing a ceramic wall-flow particulate filter such as above described. That system includes first an enclosure for the filter that is spaced from but connected to the engine exhaust manifold by a suitable length of exhaust conduit. The enclosure will generally include an integrally formed or permanently attached inlet cone for distributing the exhaust stream entering the enclosure across the diameter of the enclosure and over the inlet end of the filter.
[0015] Mounted within the enclosure is an improved ceramic honeycomb wall flow filter such as above described, the filter being disposed with its inlet end proximate to the inlet cone and its outlet end downstream from the inlet end in the direction of flow of the exhaust stream. Thus the inlet and outlet channels of the filter, being parallel with the filter central axis running from the filter inlet to the filter outlet, will be parallel with the direction of exhaust gas flow through the enclosure.
[0016] For enhanced exhaust system performance and durability, the filter includes an axial group of inlet and outlet channels, disposed on and proximate to the filter central axis, that differ at least in physical characteristics from the remaining inlet and outlet channels of the filter. Specifically, the channel walls of the axial group of channels are of higher heat capacity and/or higher gas flow resistance than the channels walls of peripheral channels disposed outwardly of the axial group with respect to the filter central axis. The higher heat capacity and/or higher gas flow resistance of the axial group effectively reduce thermal gradients arising within the filter during the soot combustion associated with filter regeneration, thereby significantly enhancing the service life of the exhaust system.
DESCRIPTION OF THE DRAWINGS
[0017] The invention is hereinafter further described with reference to the appended drawings, wherein:
[0018] FIGS. 1 and 1 a schematically illustrate a first embodiment of an exhaust filter and enclosure provided in accordance with the invention,
[0019] FIGS. 2 and 2 a schematically illustrate one alternative embodiment of an exhaust filter and enclosure provided in accordance with the invention;
[0020] FIG. 3 schematically illustrates another alternative embodiment of an exhaust filter provided in accordance with the invention; and
[0021] FIG. 4 schematically illustrates another alternative embodiment of an exhaust filter provided in accordance with the invention.
DETAILED DESCRIPTION
[0022] One approach to filter design that results in both higher heat capacity and higher gas flow resistance in the channel walls of the axial group of channels is that of increasing the channel wall thickness of the axial channel group relative to that of the peripheral channel group. The increased wall thickness adds material to the axial portion of the section filter that tends to reach higher regeneration temperatures than peripheral filter sections, thereby increasing axial heat capacity and reducing peak axial temperatures.
[0023] Further, this increased wall thickness has the additional effect of increasing the gas flow resistance of the walls, thereby shifting the balance of exhaust gas flow away from the axial channel group toward peripheral channels. This shift causes a relative reduction in soot accumulation in axial filter portions of the filter, relative to soot accumulations developed in prior art filters. Again, the result is that peak regeneration temperatures reached along axial portions of the filter are reduced.
[0024] FIG. 1 of the drawings is a schematic illustration, not in true proportion or to scale, showing a cross-sectional elevational view of a diesel filter 10 supported in an enclosure 12 with a resilient mat 11 , the enclosure being attached via an inlet cone 14 to an exhaust conduit 16 . As shown in FIG. 1 , an axial group of channels 20 disposed about the longitudinal axis 10 a of filter 10 comprise channel walls 20 a that are thicker than the channel walls 22 a of a peripheral group of channels 22 disposed about the periphery of filter 10 .
[0025] In the operation of filter 10 , diesel exhaust gases indicated by arrows 8 , comprising particulate pollutants such as particulate carbon generated by an operating engine (not shown), are conveyed via exhaust conduit 16 into inlet cone 14 and enclosure 12 , being distributed by cone 14 across the entire face of filter 10 . The incoming gases then enter filter 10 via open filter inlet channels such as channels 24 , i.e., those channels in channel groups 20 and 22 that are open at their upper ends and closed at their lower ends by channel plugs such as plugs 26 .
[0026] Due to blockage by plugs 26 the exhaust gases are forced through channel walls 20 a and 22 a and into the filter outlet channels, i.e., those channels in channel groups 20 and 22 such as channels 28 that are plugged at their upper ends and open at their lower ends. After discharge from those outlet channels the thus-filtered exhaust gases are then collected and discharged from the bottom of enclosure 12 as indicated by arrows 8 a.
[0027] FIG. 1 a is a schematic and somewhat enlarged top plan view of filter 10 taken along line 1 a - 1 a of FIG. 1 . Broken line 30 in FIG. 1 a indicates the approximate boundary between axial channel group 20 and peripheral channel group 22 .
[0028] In particular case illustrated in FIGS. 1 and 1 a , the entire wall structure of filter 10 is composed of a common porous ceramic material. Thus the heat capacity of the thickened wall structure present in axial channel group 20 is higher than that of the wall structure present in peripheral channel group 22 . In addition, thickened channel walls 20 a are less permeable to exhaust gas than channel walls 22 a , reducing exhaust gas flow through, and carbon particulate buildup on, those walls. Accordingly, peak regeneration temperatures for filter 10 that normally occur on and proximate to filter axis 10 a are lower than for prior art filters of the same average channel wall thickness, as all channel walls of the prior art filter are of the same gas permeability and heat capacity.
[0029] Of course increasing channel wall thickness comprises only one method for increasing heat capacity and/or increasing the gas flow resistance of the channel walls of the axial channel group; other methods for modifying axial group properties may also be employed. For example, the axial portions of a honeycomb structure to be used for fabricating a filter can be formed of a different ceramic composition than the composition used to form peripheral sections of the filter. The material used for the axial portion may thus have a higher heat capacity and/or a lower porosity than the material used to form the peripheral sections.
[0030] Channel coating approaches may also be useful for this purpose. Thus coatings may be selectively applied to the channel wall surfaces of the inlet and outlet channels of the axial group, the coatings being formed of ceramic materials that can increase the heat capacity and/or reduce the gas permeability of those surfaces. Such coatings may differ in composition from the composition of the channel walls, or they may be the same. Alternatively, supplemental treatments designed to modify wall permeability may be selectively applied to either the axial or the peripheral channel group, such treatments including chemical treatments to increase or decrease wall porosity and/or heat treatments to decrease such porosity.
[0031] As is evident from a study of FIGS. 1 and 1 a , the cell density of the filter (number of channels per unit of filter cross-sectional area in the plane perpendicular to the filter axis) in that embodiment of the invention is the same in both the axial and peripheral channel groups. If this is a design constraint, then reducing the sizes of the inlet and outlet channels in the axial channel group to increase channel wall thickness as shown those drawings is a straightforward approach for increasing axial heat capacity and decreasing axial gas flow.
[0032] Another approach, also based on filter designs of uniform cell density, involves the use of a wall-thickened filter design similar to that of FIG. 1 , but wherein the approach to channel wall thickening is selective. In these embodiments, wall thickening is achieved by selectively reducing the sizes of only the outlet channels in the axial channel group, with the sizes of the inlet channels in the axial group generally remaining the same. The average outlet channel cross-sectional area in the axial group is thus most generally smaller than the average outlet channel cross-sectional area in the peripheral group.
[0033] In the usual case, the average inlet channel cross-sectional area in the axial channel group will be substantially equivalent to the average inlet channel cross-sectional area in the peripheral channel group. However, equivalent functionality can be achieved by increasing the sizes of the inlet channels in the peripheral channel group relative to the sizes of the inlet channels in the axial channel group. This approach achieves channel wall thinning in the peripheral channel group relative to the axial channel group, increasing gas flow and particulate soot buildup in peripheral portions of the filter relative to gas flows and soot buildup in axial filter portions. This flow pattern thereby also reduces radial temperature gradients developed in the filter during filter regeneration.
[0034] FIGS. 2 and 2 a of the drawing comprise schematic side elevational and partial top plan views of a wall flow filter wherein wall thickening in the axial group of inlet and outlet channels has been achieved by selectively reducing the sizes of the outlet cells in the axial group. The elements and numbering of elements in FIGS. 2 and 2 a match those of corresponding elements in FIGS. 1 and 1 a.
[0035] As best seen in FIG. 2 a , inlet channels 24 located both inside and outside of axial channel group 20 in this filter are all of substantially the same cross-sectional area. However, outlet channels 26 a located within axial channel group 30 are reduced in cross-sectional area compared to outlet channels 26 located outside of the axial group. It is this reduction that produces the axial wall thickness difference between channel walls 20 a and channel walls 20 of the filter.
[0036] In yet another embodiment of the present invention the heat capacity of the axial group of inlet and outlet channels is increased by selectively increasing the cell density of the filter within the axial group. This approach, whether used alone or in combination with wall thickening or other heat capacity control methods as hereinabove described, increases the volume of channel wall material present in axial portions of the filter and thereby increases filter heat along the filter axis.
[0037] A schematic top plan view of a filter of this design is illustrated in FIG. 3 of the drawings. As shown in FIG. 3 , the cell density in axial channel group 20 approximately delineated by boundary 30 is higher than the cell density in peripheral channel group 22 . Therefore, provided that the channel wall thicknesses in channel groups 20 and 22 are substantially the same, the mass of the axial channel group, and thus the heat capacity of that group, are higher than the mass and heat capacity of the peripheral channel group.
[0038] The invention is further described below with reference to specific examples and embodiments thereof, which are intended to be illustrative rather than limiting.
EXAMPLE 1
Wall Thickened Filter
[0039] A conventional plasticized batch for ceramic honeycombs is first compounded of kaolin clay, talc, and alumina, these ingredients being provided in proportions suitable for developing a cordierite crystalline phase in the honeycomb following drying and firing. The batch further includes a methylcellulose temporary binder, a stearate lubricant, and water in a proportion sufficient to impart good plastic forming characteristics to the batch.
[0040] The batch thus provided is extruded through a steel honeycomb die of generally conventional design, wherein the plasticized mixture is conveyed into the die through an array of feedholes provided on the die entrance face. This batch is then fed within the die into an array of intersecting discharge slots opening onto the die discharge face for forming the batch into an intersecting honeycomb wall structure that is extruded from the discharge face as a honeycomb extrudate about 15 cm (6 inches) in diameter and of generally cylindrical shape wherein the honeycomb channels or cells formed by the walls run parallel to the direction of extrusion and the cylinder axis of the extrudate. The slots in the array have a starting slot width of about 0.3 mm (0.012 inches), and are spaced to produce a square-channeled cylindrical honeycomb having a cell density of 31 channels/cm 2 (200 channels/in 2 ) in planes perpendicular to the axis of extrusion of the honeycomb after subsequent firing.
[0041] To extrude honeycombs with a modified wall structure in accordance with the invention, the discharge slot array of this extrusion die is modified prior to extrusion to increase the width of the discharge slots in a central section of the die discharge face. The method of widening those slot sections is an electrical discharge machining (EDM) method such as disclosed in U.S. Pat. No. 6,570,119, incorporated herein by reference. An EDM electrode comprising an array of outwardly extending blades is selectively applied to the central section of the die discharge face to widen only slot segments within that central section. The slots in peripheral sections of the discharge face are not machined. The thus-machined slots in the central portion of the discharge space have a width of about 0.508 mm (0.020 inches).
[0042] As a natural result of this slot widening, all of the so-called “pins” defined and bounded by the widened slots in the central section of the extrusion die are reduced in size. This produces smaller inlet and outlet channel cross-sections as well as a thickened wall structure in the central portion of the cross-section of the honeycomb extrudate produced by the die.
[0043] Sections cut from the honeycomb extrudate thus provided are dried and fired to convert the sections into cordierite honeycombs. Selected sections of the honeycombs are then alternately plugged in a checkerboard pattern in the manner conventional for the production of ceramic wall flow filters. A flowable ceramic cement of conventional composition is used to plug the outlet channels on the filter entrance face and to plug the inlet channels on the filter discharge face. The cement plugs thus provided are cured by drying and firing to form the completed wall flow filter.
[0044] Calculations indicate that both the heat capacity and gas flow resistance in the central portion of the wall flow filter are significantly enhanced by the modifications in channel size and channel wall thickness in that portion. Thus the heat capacity of [each channel][the central honeycomb section] is increased by about 56% due to wall thickening. At the same time, the gas flow resistance through the central portion of the filter is increased by about 40%, due both to wall thickening and to the reduction in inlet and outlet channel size. Accordingly, a significant drop in peak regeneration temperatures along the axis of this honeycomb filter is provided.
EXAMPLE 2
Wall Flow Filter with Selective Wall Thickening
[0045] A plasticized batch for a ceramic honeycomb incorporating clay, talc alumina, a temporary binder, a lubricant, and water is compounded as described in Example 1 above. The batch thus provided is then extruded through a steel honeycomb die generally as described in Example 1 to produce a cylindrical honeycomb extrudate suitable for conversion to a wall flow filter. The slots in the discharge slot array for this honeycomb die again have a peripheral slot width of about 0.3 mm (0.012 inches), and are spaced to produce a square-channeled honeycomb cell density of 31 channels/cm 2 (200 channels/in 2 ) in the honeycomb extrudate after subsequent firing.
[0046] To extrude honeycombs with a modified wall structure in accordance with the invention, the discharge slot array of this extrusion die is again selectively modified prior to extrusion to increase the width of the discharge slots in a central section of the die discharge face. As in Example 1, the method of widening those slot sections is an electrical discharge machining (EDM) method such as disclosed in U.S. Pat. No. 6,570,119, wherein an EDM electrode comprising an array of outwardly extending blades is selectively applied to the central section of the die discharge face.
[0047] In accordance with the present example, however, EDM slot widening is carried out selectively by machining material only from alternate pins in the pin array defined by the slots, so that only those pins are reduced in size. The remaining pins in the array are not machined and therefore retain their original size.
[0048] The result of this machining approach is a modified slot array for producing a honeycomb cross-section such as shown in FIGS. 2 and 2 a of the drawings, wherein only half of the channels in the central portion of the honeycomb, like channels 26 a in FIG. 2 a , are reduced in cross-section. The slot segments in the central portion of the die discharge face are approximately 0.508 mm (0.020 inches) in width after this machining.
[0049] Sections cut from the honeycomb extrudate produced by this die are dried and fired to convert the sections into cordierite honeycombs. Selected sections of the honeycombs are then alternately plugged in a checkerboard pattern as described in Example 1. A flowable ceramic cement of conventional composition is used to plug the outlet channels on the filter entrance face and to plug the inlet channels on the filter discharge face. Among the outlet channels that are plugged on the inlet face are all of the channels of reduced cross-section produced by the selective EDM machining of the extrusion die described above. Following plugging, The cement plugs thus provided are cured by drying and firing to form the completed wall flow filter.
[0050] Again, calculations indicate that both the heat capacity and gas flow resistance in the central portion of the wall flow filter are significantly enhanced by these modifications in channel size and channel wall thickness. The heat capacity of the central portion honeycomb section is increased by about 56%, while the gas flow resistance through the central portion of the filter is increased by about 40% due a combination of wall thickening and reduced outlet channel size. A particular advantage of this design, however, is that the volume of the inlet channels within which particulate matter from the engine exhaust stream is to be trapped is not reduced in the central portion of the filter. Thus no reduction in the particulate storage capacity of the filter is incurred.
EXAMPLE 3
Wall Flow Filter with Inserted Core Segment
[0051] A plasticized batch for a ceramic honeycomb incorporating clay, talc alumina, a temporary binder, a lubricant, and water is compounded as described in Example 1 above. The batch thus provided is then extruded through a steel honeycomb die generally as described in Example 1 to produce a cylindrical honeycomb extrudate about 15 cm (6 inches) in diameter that is suitable for conversion to a wall flow filter. The slots in the discharge slot array for this honeycomb die have a slot width of about 0.3 mm (0.012 inches), and are spaced to produce a square-channeled honeycomb cell density of 31 channels/cm 2 (200 channels/in 2 ) in the honeycomb extrudate after subsequent firing.
[0052] Sections cut from the honeycomb extrudate produced by this die are dried and fired to convert the sections into cordierite honeycombs of uniform channel wall thickness and channel cross-section. Next, cylindrical core segments about 5 cm (2 inches) in diameter approximating in shape and location the central honeycomb portions bounded by broken line 30 in FIG. 3 of the drawings are core-drilled from each of the fired honeycombs, thus to produce cylindrical honeycombs with large cylindrical openings lying on the cylinder axes.
[0053] To provide a composite ceramic honeycomb from one of these core-drilled honeycomb shapes, a cylindrical honeycomb section corresponding in size and shape to the cylindrical opening is inserted into the core-drilled shape and cemented in place with a heat-settable ceramic cement. The cylindrical honeycomb section selected for this purpose has a cell density of approximately 31 channels/cm 2 (200 channels/in 2 ) and a channel wall thickness of about 0.4 mm (0.016 inches). It is formed of silicon carbide, a non-oxide ceramic material having a bulk heat capacity of approximately 1.96 J/cm 3 /° C. between 600 and 1100° C., a capacity about 24% higher that that reported for polycrystalline cordierite. A compliant heat-settable ceramic cement such as disclosed in U.S. Pat. No. 5,914,187, consisting of aluminosilicate fibers, powdered silicon carbide, a silica sol, a methylcellulose temporary binder, and water, is suitable for this purpose.
[0054] Following cementing of the silicon carbide core segment the composite honeycomb body is plugged in a checkerboard pattern as generally described in Example 1, plugging the outlet channels on the filter inlet face and plugging the inlet channels on the filter discharge face. A flowable ceramic cement of conventional composition is suitable for this purpose.
[0055] Following the drying and setting of this plugging cement, a composite wall flow filter is provided wherein the axial group of inlet and outlet channels of the cemented filter core segment have a much higher heat capacity than the peripheral group of inlet and outlet channels surrounding the core segment. Thus this composite filter exhibits significantly reduced peak temperatures along the filter axis during filter regeneration cycles than unitary filters composed only of cordierite. Thus it can survive multiple filter regenerations without cracking.
[0056] Although a composite filter such as described above in Example 3 above can exhibit acceptable thermal durability, the substantially differing thermal expansion characteristics of the core and peripheral ceramic materials place a significant strain on the compliant cement joint between the two filter segments. This joint therefore remains a potential source of filter failure. An alternative composite filter design that solves this problem is described in Example 4 below.
EXAMPLE 4
Composite Filter Design
[0057] A fired and core-drilled cordierite ceramic honeycomb shape made as described in Example 3 above is selected for further processing. Into the central opening of this shape is inserted a cylindrical cordierite honeycomb core element matching the central opening in size and shape. The cordierite core element selected for insertion has a channel wall thickness close to the channel wall thickness of the core-drilled honeycomb shape, but it has a higher cell density of about 46.5 cells/cm2 (about 300 cells/in 2 ) of honeycomb cross-section.
[0058] This core element is cemented in place with a flowable ceramic cement of conventional composition matching the cement composition used for channel plugging in Examples 1-3 above. Thereafter the inlet and outlet channels of the cemented core-drilled shape and honeycomb core are plugged in a checkerboard pattern as described in Example 1 above.
[0059] Drying and setting of the ceramic cements thus applied produces a composite wall flow filter composed entirely of cordierite. However, the ceramic core element has higher bulk density by virtue of its higher cell density. Thus the heat capacity of the core element is approximately 20% higher than the heat capacity of the core-drilled filter periphery, and the core exhibits increased gas flow resistance (a pressure drop increase of about 5%) due to its reduced channel size. While not large, this differential in heat capacity and flow resistance will be sufficient to substantially reduce the incidence of regeneration cracking in the composite honeycomb. Moreover, as the thermal expansion properties of the cordierite core substantially match those of the peripheral cordierite honeycomb, problems relating to expansion mismatch stresses in the composite structure are entirely avoided.
[0060] Although the foregoing examples are illustrative of filter designs incorporating a step change in filter properties from the core to the periphery, it will be apparent that multi-step or even smoothly graded changes in properties are also effective to increase the average heat capacity or gas flow resistance of the core relative to peripheral sections of such honeycombs. For example, the filter can be designed with continuously varying wall properties from the central channels to the outer channels by having the wall thickness vary linearly with distance from the center to the outside, e.g. from 0.024 inches to 0.016 inches from the core to the periphery.
[0061] FIG. 4 of the drawings schematically illustrates a cross-sectional design for a filter based on graded wall thickness changes. As shown in the filter cross section of FIG. 4 , the walls of the honeycomb inlet channels 24 and outlet channels 26 increase continuously in thickness from the outer portion of the cross-section to the center thereof. Accordingly, the average channel wall thickness and heat capacity in the central filter section bounded by broken line 30 in this design are higher than the average wall thicknesses in the outer portion of the cross-section.
[0062] Even more preferably, filter wall thicknesses can be varied in direct proportion to the variations in filter temperature that can arise during uncontrolled regeneration. Thus the filter could have a maximum wall thickness (e.g. at 0.024 inches) where the highest uncontrolled regeneration temperatures are observed in similarly sized test filters of uniform wall thickness, and a minimum wall thickness (e.g. at 0.016 inches) where such observed temperatures are the lowest. All other wall thicknesses would then be proportional in thickness to the uncontrolled regeneration temperatures observed at those particular wall locations in a uniform filter. As a specific example of such a design, if a maximum observed regeneration temperature in a uniform filter is 1000° C. and a minimum observed temperature is 600° C., then a wall in that filter having a regeneration temperature of 800° C. would remain at 0.020 inches thickness, while a wall having a temperature of 900° C. would be increased in thickness to 0.022 inches.
[0063] The same concept can be extended across the entire filter, and in fact applied in both axial and radial filter dimensions. Moreover, iterative changes to any particular filter design can be made by initiating uncontrolled regenerations in a first-generation thickness-adjusted design, and thereafter readjusting wall thicknesses in second- and later-generation designs to further reduce temperature gradients and overall filter mass.
[0064] A further important advantage shared by all of the filter designs of the invention is the potential for providing more uniform and complete regeneration than prior art filters. This is due primarily to the fact that regeneration temperatures in exterior portions of the filters of the invention can be higher than can be safely attained in filters of uniform wall thickness.
[0065] It is known that filters of sufficient wall thickness, e.g., of 0.020 inches thickness or higher, can be designed to survive uncontrolled regenerations despite the presence of high temperature gradients, but such filters may not regenerate completely where peripheral soot concentrations and regeneration temperatures are relatively low. On the other hand, a filter of equivalent overall mass having, for example, exterior walls of 0.016 thickness and interior walls of 0.024 inches will exhibit higher peripheral temperatures than the uniform filter, due to a more uniform soot redistribution and reduced peripheral mass. Thus soot combustion across the filter diameter will generally be more uniform and complete.
[0066] While the foregoing examples are illustrative of specific embodiments of the invention it will be recognized that similar advantages in filter efficiency and performance may be realized through the use of alternative materials, designs and procedures within the scope of the appended claims. | 4y
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to high performance, compact electro-acoustic transducers. More specifically, the invention relates to non-woven composite spiders used in these compact electro-acoustic transducers.
[0002] A spider and surround provide a suspension system for a diaphragm in an electro-acoustic transducer. Both the spider and surround support the diaphragm as it moves along the transducer axis and prevents a voice coil attached to the diaphragm from rubbing against or hitting the transducer's pole piece or pole plate. The spider and surround are typically ring-shaped having an inner and outer perimeter. The outer perimeters of the spider and surround are attached to the transducer's basket. The inner perimeter of the surround is typically attached to the outer edge of the diaphragm. The inner perimeter of the spider is typically attached near a narrow portion of the diaphragm or to a bobbin.
[0003] Spiders are typically made by dipping a woven fiber such as cotton in a phenolic resin. The woven cotton provides strength and fracture toughness to the spider and the phenolic resin provides enough stiffness to maintain the spider's shape while providing enough compliance to allow the diaphragm to freely move along the transducer axis. The phenolic resin coats the fibers and forms bridges between the warp and weft yarns where the yarns overlap. The resin bridges provide stiffness to the coated fiber while allowing air to pass through interstices between the woven fabric. The phenolic-resin-fiber-coated spider is herein referred to as the typical spider.
[0004] As the diaphragm moves in and out along the transducer axis, the spider is repeatedly flexed or stretched to accommodate the movement of the diaphragm. The repeated flexing/stretching of the spider typically leads to a fatigue-type failure, thereby shortening the life of the electro-acoustic transducer. Furthermore, the flexing/stretching of the spider generally reduces the stiffness of the spider over time (ageing), which may affect the acoustic properties of the electro-acoustic transducer.
[0005] Consumer pressure favors the design of high-power, compact electro-acoustic transducers, which usually requires longer stroke distances for the diaphragm. The longer stroke distance generates larger cyclic stresses in the spider and accelerates the ageing of the spider and shortens the live of the spider. Therefore, there remains a need for compact spiders that can support the longer stroke distances of the diaphragm with increased fatigue and ageing resistance.
SUMMARY OF THE INVENTION
[0006] A spider for high-power, compact electro-acoustic transducers comprises a non-woven fiber blend encased in a thermoplastic elastomer. The spider is capable of supporting the longer stroke distances of the high-power, compact electro-acoustic transducers and exhibits improved fatigue and ageing resistance.
[0007] One embodiment of the present invention is directed to a spider comprising a non-woven fiber mat embedded in an elastomeric matrix. In one aspect, the elastomeric matrix is impermeable to air. In one aspect, the elastomeric matrix is a polyurethane. In one aspect, the non-woven fiber mat is a polyester. In one aspect, the non-woven fiber mat is a fiber blend. In one aspect, the non-woven fiber is a blend of a polyester fiber and an aramid fiber. In one aspect, the fraction of aramid fiber in the fiber blend is between 0.1 and 0.9. In one aspect, the fraction of aramid fiber in fiber blend is between 0.4 and 0.6. In one aspect, the elastomeric matrix is selected from a group comprising a thermoplastic polyurethane, a two-part polyurethane, a silicone, a thermoplastic rubber, TPSiV, and combinations thereof. In one aspect, the non-woven fiber is selected from a group comprising a cotton, a polyester, a nylon, a cellulose, an aramid, a polyphenylene sulfide, a polyacrylonitrile, and combinations thereof. In one aspect, the fiber blend comprises polyester fiber and polyacrylonitrile fiber. In one aspect, the fiber blend comprises polyester fiber and polyphenylene sulfide fiber. In one aspect, the spider is vented. In one aspect, the spider has an elastomer-rich external surface
[0008] Another embodiment of the present invention is directed to an electro-acoustic transducer comprising: a basket supporting a magnet; a diaphragm capable of movement relative to the basket, the diaphragm attached to a voice coil characterized by an axis, the voice coil generating a magnetic field in response to an input signal applied to the voice coil, the interaction of the generated magnetic field interacting with a magnet field of the magnet causing the diaphragm to move along the axis; a surround having a first perimeter attached to the basket and a second perimeter attached to the diaphragm at a first point along the axis; and a composite spider having a first portion attached to the basket and a second portion attached to the diaphragm at a second point along the axis, wherein the composite spider is impermeable to air. In one aspect, the composite spider comprises a non-woven fiber. In one aspect, the non-woven fiber is a polyester fiber. In one aspect, the non-woven fiber is a fiber blend. In one aspect, the non-woven fiber is a blend of a polyester fiber and an aramid fiber. In one aspect, the aramid fiber is a meta-aramid fiber. In one aspect, the aramid fiber is a para-aramid fiber. In one aspect, the composite spider comprises an elastomeric matrix. In one aspect, the elastomeric matrix is a polyurethane. In one aspect, the non-woven fiber blend comprises a polyester fiber and a polyacrylonitrile. In one aspect, the composite spider is vented. In one aspect, the composite spider is characterized by a fiber-rich interior volume between elastomer-rich volumes, the elastomer-rich volumes forming external surfaces of the composite spider.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention will be described by reference to the preferred and alternative embodiments thereof in conjunction with the drawings in which like structures are referenced with like numbers.
[0010] FIG. 1 is a sectional view of an embodiment of the present invention.
[0011] FIG. 2 is a diagram illustrating an embodiment of the present invention.
[0012] FIG. 3 is a graph of stiffness as a function of cycles for an embodiment of the present invention and for a typical spider.
DETAILED DESCRIPTION
[0013] FIG. 1 is a sectional view of an embodiment of the present invention. In FIG. 1 , diaphragm 110 is supported by a surround 120 and a spider 125 . An outer edge of the diaphragm 110 is circumferentially attached to an inner edge of the surround 120 . An inner edge of the diaphragm 110 is attached to a bobbin 150 . An inner edge of the spider 125 is attached to the bobbin 150 . An outer edge of the surround 120 and an outer edge of the spider 125 are attached to a basket 130 . The surround 120 and spider 125 preferably restricts the movement of the diaphragm 110 along an axis of the diaphragm 110 indicated by axis 190 .
[0014] Basket 130 supports a magnet 140 , a pole plate 142 and a rear pole plate and pole piece 144 . Bobbin 150 is disposed within an annular gap 145 formed between the pole plate 142 and pole piece 144 . A wire coil 155 is wound around the bobbin 150 , the bobbin and coil comprising a voice-coil, and receives an electrical signal representing an acoustic signal. The wire coil 155 generates a magnetic field in response to the applied electrical signal, which interacts with the field produced by magnet 140 causing diaphragm 110 to move in the directions indicated by axis 190 .
[0015] A dust cover 115 attached to diaphragm 110 prevents particles from accumulating in the gap 145 . A narrow gap is desired for a strong magnetic field in the gap. As the gap is narrowed, however, the requirements for keeping the voice-coil centered while it moves along the diaphragm axis relative to the basket increases. Keeping the voice-coil centered at tighter tolerances required by a narrower gap typically requires a stiffer surround/spider suspension system, which requires more force to move the diaphragm at frequencies below the mechanical resonance frequency of the moving structure.
[0016] In some embodiments, spider 125 is a fiber composite. The fiber may be a woven or non-woven fiber and may be a blend of fibers. Examples of fibers that may be used alone or in combination include cotton, polyester, polycotton, aramid, nylon, cellulose, polyphenylene sulfide, polyacrylonitrile, and combinations thereof. Aramids include, meta-aramids such as polymetaphenylene isophtalamides, which includes Nomex and para-aramids such as p-phenylene terephtalamides, which includes Kevlar.
[0017] The fiber composite matrix material is preferably an elastomer such as, for example, a urethane. Further examples of suitable elastomers include silicones, thermoplastic rubbers, and thermoplastic silicon vulcanizate (TPSiV) rubbers.
[0018] FIG. 2 is a diagram illustrating a process for forming a spider. In FIG. 2 , a fiber mat 215 is sandwiched between elastomer sheets 210 . The sandwich is placed in a die 240 and held at a temperature and pressure such that the elastomer sheets flow into the fiber mat and create a formed composite spider 250 comprising fibers 258 embedded in an elastomeric matrix 254 . In some embodiments, the formed composite spider 250 retains a sandwich appearance in that the composite spider has an interior, fiber-rich volume between elastomer-rich external volumes that form the external surfaces of the composite spider. The fiber-rich volume may contain substantially all of the fiber with the elastomer filling the spaces between the fiber. The elastomer-rich volume is substantially all elastomer such that little or no fibers penetrate the surface of the composite spider. The sandwich may be heated indirectly through the die or directly heated by induction heating, for example. Die stops (not shown) may be used to control a thickness dimension for the formed composite.
[0019] The selection of the forming temperature and pressure typically depend on the specific elastomer selected and may be constrained by the specific fiber. For example, if the elastomer is a polyurethane such as Steven PUR MP 1880 available from JPS Elastomerics Corp. of Holyoke, Mass., forming temperatures may be selected from a range of 170-190° C. Forming pressures may be selected from the range of 2-75 MPa, preferably from the range of 4-8.5 MPa, and more preferably from the range of 6.8-8.5 MPa. Other temperatures and pressures may be selected depending on the specific elastomer selected for the matrix material.
[0020] Examples of composite spider compositions illustrating some of the variations within the scope of the present invention include: a layer of non-woven Nomex fiber sandwiched between polyurethane sheets hot pressed at 177° C. and 17 MPa; a layer of non-woven Kevlar fiber sandwiched between polyurethane sheets hot pressed at 177° C. and 17 MPA; a layer of non-woven polyester fiber sandwiched between polyurethane sheets hot pressed at 177° C. and 17 MPa; a layer of non-woven polyester fiber such as a Lutradur non-woven fiber having a density of about 5.3 oz/yd 2 available from Freudenberg of Durham, N.C. sandwiched between polyurethane sheets hot pressed at 179° C. and 17 MPa; a 50/50 polyester/Nomex non-woven fiber blend sandwiched between polyurethane sheets hot pressed at 188° C. and 65 MPa; and a 50/50 polyester/polyacrylonitrile non-woven fiber blend sandwiched between polyurethanes hot pressed at 188° C. and 65 MPa.
[0021] Unlike the typical spider, the elastomer matrix of embodiments of the present invention generally make such a spider air impermeable and can create a pressure imbalance between a front side of the spider and a rear side of the spider as the spider is stretched within the basket. The pressure imbalance may be reduced by providing one or more openings in the basket to allow the volumes above and below the spider to equalize their pressures. The openings may be covered with a screen to prevent dust particles from entering the volume below the spider, lodging themselves in the gap 145 , and possibly affecting the performance of the electro-acoustic transducer. The dust screen adds to the cost of the electro-acoustic transducer that is not usually required in a typical spider. The added cost, however, is offset by the more desired characteristics of a fiber-elastomer composite spider. Alternatively, the spider may be vented to allow pressures on each side of the spider to equalize with each other. Vents in the spider may include holes or slits in the spider.
[0022] FIG. 3 is a graph illustrating the stiffness of phenolic-resin-coated-fiber spider samples 350 and of fiber-elastomer composite spider samples 310 . Samples of both the typical spider and elastomeric fiber composite spiders were fabricated and tested in the same fatigue testing jig. Each sample was fatigue tested under a 22 mm peak-to-peak displacement for up to 500,000 cycles. The stiffness at each cycle was calculated as an average of the upward and downward slopes of the force-deflection curve. Comparing the typical and fiber-elastomer composite samples in FIG. 3 indicates that the fiber-elastomer composite spiders retain about 80% of their original stiffness. In contrast, the typical spider retains less than about 25% of its original stiffness. The high stiffness retention exhibited by the fiber-elastomer composite spider is believed to be desirable and implies that the performance of an electro-acoustic transducer incorporating such a spider should not degrade due to degradation of the spider.
[0023] Having thus described at least illustrative embodiments of the invention, various modifications and improvements will readily occur to those skilled in the art and are intended to be within the scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention is limited only as defined in the following claims and the equivalents thereto. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED-RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0003] Not Applicable.
FIELD OF THE INVENTION
[0004] The invention disclosed broadly relates to the field of cooling of semiconductor chips, and more particularly relates to attachment of heat sinks to semiconductor chips.
BACKGROUND OF THE INVENTION
[0005] The performance of integrated electronics chips has increased dramatically over recent years. This increased performance has been achieved in part by increasing the chip operating frequency which has resulted in greater chip power (Watts) and chip power density (Watts/cm2). This has increased the need for efficient thermal power management to conduct the heat away from the chip to the ambient surroundings using for example heat sinks, fans, vapor chambers, liquid coolers and other means to cool the chips to maintain an acceptable operating temperature. Today's powerful processors generate so much heat that chips will thermally overheat if the thermal cooling solution is not operational even for a short period of time. A heatsink is a device that is attached to the microprocessor chip to keep it from overheating by providing a thermal conduction path of the heat generated by the chip to the ambient environment by moving air over the heat sink. Basic heat sink structures have a heat spreader which makes thermal contact with the chip via an interface of a thermally conductive adhesive and fins which provide a large surface area to transfer the heat to the ambient air environment. Typically a fan is used to provide an air flow over the fins to optimize the heat transfer from the heat sink to the ambient air.
[0006] Most commercially available computers incorporate a heat sink directly attached to the chip. This combination of the chip and heat sink is often referred to as a “chip package.” The basic design of a chip package is shown in FIG. 1 in which a heatsink 102 is mounted on a chip 120 . The heatsink 102 shown is a conventional passive metal heat sink with fins. The chip 120 makes thermal contact with the heat sink 102 through a thermal interface material 111 . The chip 120 is attached to a chip carrier 122 which has a pin grid array and interfaces to an electrical socket 110 which is mounted onto a printed circuit board 125 . The heat sink 102 is secured to the chip 120 by a frame 112 and mounting screws 116 in order to inhibit horizontal and vertical movement of the heat sink as would occur under external forces, including shock and vibration of the system. FIG. 2 shows the top view of the chip package of FIG. 1 .
[0007] Clearly this design is meant to stabilize and constrain the heatsink 102 and it is effective in doing so. The problem inherent in this design, however, is that the rigid assembly results in deformation of the entire package due to differences in the coefficient of thermal expansion (CTE) between the heatsink 102 and the chip package assembly. The need to constrain the mechanical motion of the heat sink 102 due to external forces (shocks) requires a rigid, non-compliant attachment which unfortunately results in package deformation. Contributing to this problem is the rigidity and non-compliance inherent in heatsinks, which are usually metal structures. Currently produced heatsinks fail to provide for the structural stresses and strains generated during the operation of the electronic device (the chip 120 ). Therefore, there is a need for a solution that overcomes the above shortcomings of the prior art.
SUMMARY OF THE INVENTION
[0008] Briefly, according to an embodiment of the invention, a system and method of attaching a heat sink to an integrated circuit chip includes providing a compliant material for constraining the heat sink mechanical motion while simultaneously allowing for thermal expansion of the heat sink; and providing at least one mechanical limit stop disposed between the heat sink and a frame. Additionally, the invention provides for placing the compliant material between the heat sink and the at least one mechanical limit stop. Further horizontal constraint pads are positioned between the heat sink and the at least one mechanical limit stop. Vertical constraint pads can be positioned between the heat sink and the at least one mechanical limit stop.
[0009] According to another embodiment of the present invention, a structure for attaching a heat sink to an integrated circuit chip includes a set of ball bearings positioned to allow motion of the heat sink in the X and Y directions while constraining motion in the Z direction. The ball bearings are attached using braces with each ball bearing positioned at the corner sidewalls of the heat sink such that force applied to the ball bearing from the heat sink will prevent mechanical movement of the heat sink in a vertical direction.
[0010] According to another embodiment of the present invention, a structure for attaching a heat sink to an integrated circuit chip includes a servo control system. The servo control system includes a voice coil motor to actuate the heat sink. Further, at least one gap sensor creates a position signal between the heat sink and a fixed frame.
[0011] According to another embodiment of the present invention, an attachment structure for attaching a heat sink to an integrated circuit chip includes: a platform for the heat sink; a plurality of horizontal limit stops including compliant material for constraining mechanical motion of the heat sink while allowing for thermal expansion of the heat sink in a chip package, wherein each horizontal limit stop is positioned on the platform such that the compliant material makes contact with the heat sink and the chip; and a plurality of vertical limit stops including compliant material, wherein each vertical limit stop is positioned on the platform such that the compliant material makes contact with a bottom surface of the heat sink and the chip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] To describe the foregoing and other exemplary purposes, aspects, and advantages of the present invention, we use the following detailed description of exemplary embodiments of the invention with reference to the drawings, in which:
[0013] FIG. 1 is an illustration of a cross-section view of a basic chip package design with a passive heatsink, according to the known art;
[0014] FIG. 2 is an illustration showing the top view of the basic chip package of FIG. 1 , according to the known art;
[0015] FIG. 3 a is a side view of a chip package assembly according to an embodiment of the present invention;
[0016] FIG. 3 b is a top view of the chip package assembly according to an embodiment of the present invention;
[0017] FIG. 3C is a detailed view of the corner of the chip package assembly according to an embodiment of the present invention;
[0018] FIG. 4 is a 3D view of the chip package assembly according to an embodiment of the present invention;
[0019] FIG. 5 a is a side view of an illustration of a chip package assembly with ball bearings, according to an embodiment of the present invention;
[0020] FIG. 5 b is a top view of an illustration of a chip package assembly with ball bearings, according to an embodiment of the present invention;
[0021] FIG. 6 is a close-up cut-away view of one of the ball bearings of FIG. 5 , according to an embodiment of the present invention;
[0022] FIG. 7 is a side view of a chip package assembly using non-contact voice coil motors, according to an embodiment of the present invention;
[0023] FIG. 8 is a top view of the assembly of FIG. 7 , according to an embodiment of the present invention;
[0024] FIG. 9 is an exploded view of a voice coil motor, according to an embodiment of the present invention; and
[0025] FIG. 10 shows a diagram of the servo control system of FIG. 7 , according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0026] We describe an attachment method for a heat sink, according to an embodiment of the present invention. As will be shown, the present embodiment changes the mechanical boundary conditions of the heat sink to allow slowly varying relative motion while still providing mechanical support for shock inputs. This is accomplished by changing the method of heat sink attachment, such that mechanical motion is limited under shock but provides compliance for thermal expansion. As such this will reduce the heat sink/package mechanical interaction due to the mismatch of the coefficients of thermal expansion (CTE) for those materials. A CTE mismatch occurs when the heat sink material experiences thermal expansion at a different rate than that of the frame. This is one of the main causes of package deformation.
[0027] Referring now in specific detail to the drawings, and particularly FIG. 3 a there is shown a side view of a chip package assembly 300 with attached heat sink 302 . According to an embodiment of the present invention, pads 312 and 314 are fabricated from a highly damped elastomeric material such as those commercially available as C- 1105 from EAR Specialty Composites. These materials are also viscoelastic in that they exhibit both the properties of a viscous liquid which “flows” at slow deformation speeds and an elastic solid at higher speeds. These materials have a frequency dependent elastic modulus which increases at higher frequencies, thus becoming stiffer if the load changes quickly.
[0028] FIG. 3 b shows a top view of the chip package assembly 300 . The elastomeric material is used in the X and Y pads 314 and 318 at the corner mounts of the heat sink 302 to control motion of the heat sink 302 in the X and Y directions as well as the Z pads 312 at the bottom side of the heat sink 302 corners to control motion in the Z direction.
[0029] As shown in FIG. 3 b the X and Y pads 314 and 318 are disposed at the corner mounts, positioned between the heat sink 302 and the horizontal limit stops 316 . Pads 312 are also positioned between the heat sink 302 and the vertical stops 308 . The viscoelastic material is sufficiently rigid that it limits mechanical motion in the presence of shocks; yet it provides compliance sufficient to handle the thermal expansion mismatch of the heat sink/package 300 . The positioning of the pads will reduce the effects of shock from X, Y, and Z forces exerted on the heat sink 302 . Positioning the pads 314 at the bottom only will limit the effects from a Z force shock only.
[0030] The key advantages of employing the pads 312 , 314 , 318 at the corner mounts and the bottom of the heat sink 302 are: 1) they allow mechanical motion from thermal expansion; and 2) they restrict mechanical motion due to shock. The key aspects of the pads are the viscoelastic properties of the material used and the positioning of the pads with respect to the heat sink 302 .
[0031] FIG. 3 c presents a detailed view of one corner of the the chip assembly package 300 of FIGS. 3 a and 3 b. This view shows the corner of the heat sink 302 which is abutted by pads 314 and 318 which may be, for example, attached to the limit stop 316 and the heat sink 302 with an adhesive glue. When a force F 2 is applied to the heat sink 302 , pad 318 is compressed. However, as the elastic modulus of the pad 318 is frequency dependent, the restoring force would depend upon the frequency of the applied force. For slowly varying forces such as would occur with thermal expansion, pad 318 would be soft, but for higher frequency forces the pad 318 would be very stiff. This allows the heat sink 302 to expand due to temperature changes, but provides constraint of the heat sink 302 for high frequency forces. Note that pad 314 experiences a shear force during the applied force F 2 and allows movement of the heat sink 302 both for thermal and high frequency forces.
[0032] For a force F ( 320 ) in the X, Y plane the pad 314 would experience a force F 1 =F cos(θ) and pad 318 would experience a force F 2 =F sin(θ). Each pad would respond as described above.
[0033] As the package may experience a force in any arbitrary direction, the heat sink 302 can experience a force which has components in the X, Y and Z planes. As shown in the three-dimensional (3D) view of FIG. 4 , the pads in the Z direction will compress when a force has a downward Z component. The clamp 304 holds the center of the heat sink 302 in the Z direction and applies a downward bias force on the pads 312 which prevents the heat sink from lifting off the chip 320 when there is an upward Z component. To minimize the deflection of the pad 312 to the bias force a higher modulus elastomer may be deployed or the pad thickness may be reduced. In one example the dimension of the pads may measure 5 mm by 5 mm and have a thickness of 1 mm.
[0034] Another embodiment is shown in FIG. 5 a in which ball bearings 504 allow the heat sink 502 to move in a horizontal direction while limiting motion in the vertical direction. FIG. 5 b illustrates how the horizontal motion is impeded by pads 514 secured to horizontal stops 516 . The pads 514 are viscoelastic as shown in FIG. 4 . The ball bearings 504 are secured by braces 506 attached to the horizontal stops 516 . Note that these bearings 504 are only at the bottom, not the sides.
[0035] FIG. 6 shows a close-up view of one of the ball bearings 504 . The arrows encircling the ball bearing 504 indicate how the ball bearing 504 can rotate, or spin, while remaining in a fixed position. The heat sink 502 is in contact with the top portion of the ball bearing 504 . A slight horizontal motion of the heat sink 502 will produce a swiveling of the ball bearing 504 . The horizontal stops 516 with the pads 514 attached will constrain the heat sink 502 from excessive movement.
[0036] It should be understood that what has been discussed and illustrated serves to provide examples of the possible embodiments within the spirit and scope of the invention; they should not be construed to limit the invention. One with knowledge in the art, after following the discussion and diagrams herein, can employ any viscoelastic material having the same properties as C- 1105 bearings from EAR, or flexures properly positioned at the corner mounts as discussed above to provide the advantages of a reduction in package deformation while allowing for limited mechanical motion due to thermal expansion.
[0037] Another approach to limit mechanical motion in the presence of shocks and/or vibrations while allowing for slow thermal expansion is to deploy active servo control of the heat sink. H. Newton, Newton's Telecom Dictionary, 22 nd Edition, Copyright © 2006 Harry Newton, defines a servo as: “Servo: short for servomechanism. Devices which constantly detect a variable, and adjust a mechanism to response to changes.”
[0038] Another embodiment of the present invention is shown in FIG. 7 wherein active servo control is employed to constrain the movement and/or expansion of a heat sink 702 . Voice coil motors are used to actuate the heat sink 702 . FIG. 7 shows one example of a voice coil motor 728 which controls the X motion of one corner of the heat sink 702 . Each voice coil motor includes: a voice coil 726 mounted onto the heat sink 702 and a magnetic circuit consisting of permanently affixed magnets 720 and 722 , with flux return paths and mechanical assembly to hold the magnets in place 724 . The servo method of heat sink constraint differs from the previously described embodiments in that there may be no actual contact made between the heat sink 702 and the board 744 . This is indicated in FIG. 7 by the gaps 799 .
[0039] FIG. 8 shows a top view of the assembly of FIG. 7 with Z direction voice coil motors 710 and 712 . FIG. 8 also shows the voice coils for the X and Y directions, 724 , 726 and 734 and 736 , in opposite corners, which are part of the voice coil motor assembly. For example 726 is the voice coil for voice coil motor 728 as shown in FIG. 7 .
[0040] Gap sensors 735 , 737 , 725 , 727 measure the location of the heat sink 702 edge to a fixed frame in the X and Y directions. Similarly, gap sensors 704 and 706 measure the location of the heat sink 702 to the frame 744 in the Z direction. One example of gap sensors may include proximity sensors using well known capacitance or eddy current measurement methods. The capacitance between two plates is proportional to 1/d, where d is the gap between the plates, thereby the gap can be measured by measuring C and computing 1/C. The voice coil motor and gap sensors are used in a servo loop to control the location of the heat sink 702 relative to the frame 744 .
[0041] As shown in FIG. 8 two vertical axis voice coil motors 710 and 712 are disposed in opposite corners of the top frame 744 to maintain the Z height of the heat sink 702 relative to the frame 744 . For example, a Z position signal Z gap 704 is compared to a Z gap target and the difference between the Z gap target and Z gap 704 will create an error signal as shown in FIG. 10 which is input to the servo controller Gc which produces a signal to control the current to the physical plant Gp which includes Z voice coil motors 710 and heat sink 702 . The current applied to Z voice coil motor 710 will produce a force on the heat sink 702 to actuate it in the +Z or −Z direction until the Z gap value is equal to the target value. Similarly a second servo loop using Z gap 706 would be running in parallel, which for example may have a Z gap target 706 equal to the Z gap 704 target 704 , to maintain the heat sink 702 parallel to the frame 744 .
[0042] To maintain the X and Y position of the heat sink 702 , horizontal axis voice coils 724 , 726 are deployed in one corner of the heat sink 702 and voice coils 734 and 736 are deployed in the opposite corner of the heat sink 702 . These voice coils are part of a voice coil motor assembly, an example of which is shown in FIG. 7 as 728 . A position signal from the difference of Gap X=Xgap 735 −Xgap 725 can be generated by measuring the gap in the X direction using Xgap sensors 735 and 725 and taking the difference between the two signals.
[0043] Similarly, by monitoring the gap in the Y direction using Y gap sensors 737 and 727 a position signal can be generated from the difference of Gap Y=Ygap 737 −Ygap 727 . These signals are input to the servo control system as shown in FIG. 10 . For example, GapX would be compared to a GapX target, which for example may have a value of zero such as would occur when Xgap 735 is equal to X gap 725 and the heat sink 702 is centered with respect to the center of the frame 744 .
[0044] The difference between the GapX and Gap X target will create an error signal as shown in FIG. 10 which is input to the servo controller, Gc, which produces a signal to control the current to Gp, the physical plant, which includes the voice coil motor and heat sink 702 . The current applied to the voice coils 726 , 736 to produces a force on the heat sink 702 to actuate it in the +X or −X direction until the GapX value is equal to the Gap X target value.
[0045] Referring to FIG. 9 there is shown an exploded top view of voice coil motor (VCM) 728 located in the right quadrant of FIG. 8 . This VCM produces a motion of the heat sink 702 in the X direction when a current is applied to the voice coil 726 . The VCM is comprised of permanent magnets 720 and 722 , each of which is made of two magnets with reverse polarity. The magnets 720 and 722 and flux return plates 721 , 723 are held in place by a non-magnetic mechanical fixture 724 . When a current passes through the coil 726 , the coil experiences a force in the +X or −X direction dependent on the direction of the current and transfers that force to the heat sink. Similarly a current passing through voice coil 736 applies a force in the X direction on the opposite corner of the heat sink 702 .
[0046] The coils 726 and 736 are attached to the heat sink 702 and using the servo control system the heat sink 702 will remain centered with respect to the frame 744 in the X direction as previously described while allowing thermal expansion of the heat sink 702 . Similarly, when using the servo control system with voice coils 724 and 734 , the same control of the heat sink 702 in the Y direction can be achieved. In the Z direction, the gap 799 between the heat sink 702 and the frame 744 will be held to a predetermined target value, such that the heat sink 702 remains parallel to the frame 744 .
[0047] Therefore, while there have been described what are presently considered to be the preferred embodiments, it will be understood by those skilled in the art that other modifications can be made within the spirit of the invention. Solutions which combine elements of the described solutions including using mechanical and servo control systems are also possible. | 4y
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BACKGROUND
[0001] 1. Field
[0002] One or more embodiments described herein relate to processing substrates including semiconductor substrates.
[0003] 2. Background
[0004] Semiconductor devices and flat panel displays are made by performing photographing, etching, diffusion, deposition, and other processes on a substrate. These processes are performed in an apparatus having moving parts that can damage or otherwise adversely affect the performance of the finished substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIGS. 1 a to 1 c are diagrams showing one type of substrate supporting apparatus.
[0006] FIGS. 2 to 4 are diagrams showing an embodiment of another type of substrate supporting apparatus.
[0007] FIG. 5 is a diagram showing an embodiment of another type of substrate supporting apparatus.
[0008] FIGS. 6 a to 6 c are diagrams showing operation of one or more of the foregoing embodiments of the substrate supporting apparatus.
DETAILED DESCRIPTION
[0009] FIG. 1 a shows one type of substrate processing apparatus that includes upper and lower electrodes 110 and 120 in a chamber 100 . In operation, a substrate is transferred (e.g., by a robot) into the chamber through a gate valve G and placed on the lower electrode. A supporting apparatus 130 is used to place the substrate on the lower electrode, and/or to withdraw the substrate from the chamber once processing is finished.
[0010] The substrate supporting apparatus includes a plurality of lift pins 131 that pass through the lower electrode, a pin plate 132 provided with the lift pins, and a lift unit 133 for lifting the pin plate up and down.
[0011] When gate valve G is opened in a state shown in FIG. 1 a , a robot arm carrying the substrate is advanced into the chamber through the gate valve. As shown in FIG. 1 b , when the robot arm advances into the chamber, pin plate 132 is immediately lifted causing lift pins 131 to pass through lower electrode. When the lift pins project out of the lower electrode, substrate S carried is transferred onto the lift pins from the robot. When the pin plate is lowered, the lift pins pass back through the lower electrode to thereby place the substrate on the lower electrode as shown in FIG. 1 c.
[0012] When the lift pins contact the substrate during lifting and lowering, foreign materials attached to uppermost parts of the pins may cause spots to form on the substrate. Also, the positions of the lift pins are fixed and cannot be changed because, in any other position, the pins would not be able to pass through the respective holes in the lower electrode. Also, lift pins may damage patterns formed on the substrate, and further damage may result when processes are performed without first detecting that one or more of the lift pins are broken.
[0013] FIGS. 2 and 3 show an embodiment of another type of substrate supporting apparatus 30 . This apparatus includes first and second supporters 31 a and 31 b provided in parallel at respective sides of lower electrode 20 . The lower electrode is interposed between the first and second supporters and first and second combining holes 31 ah and 31 bh are formed on the first and second supporters respectively.
[0014] First shafts 32 a are inserted into three of the combining holes 31 ah , and second shafts 32 b are inserted into three of the combining holes 31 bh . This insertion may be performed, for example, by screwing the shafts into the holes. Wires 33 are connected to respective pairs of the shafts 32 a and 32 b that face each other. In FIG. 3 , three wires are shown as being used. However, a different number of wires (e.g., 1 or more) may be used in other embodiments. Also, the gap or spacing between the wires may be determined, for example, based on the positions of the combining holes.
[0015] The position of the wires can be set or changed based on (e.g., to correspond to or avoid) patterns formed on the substrate. By setting or changing the position of the wires, it is possible, for example, to prevent the wires from contacting and therefore damaging portions of the substrate that contain patterns.
[0016] The substrate supporting apparatus also includes lift units 33 a and 33 b which are respectively connected to lower ends of first and second supporters 31 a and 31 b . The lift units operate to lift the first and second supporters 31 a and 31 b up and down as necessary before, during, and/or after processing.
[0017] The substrate supporting apparatus may also include a sensor 34 to detect the presence of a break in one or more of the wires. The sensor may detect a break (or short) by applying a signal (e.g., a current, voltage, or power signal) to one end of the wire and then detecting the presence or absence of the signal at an opposing end of the wire. Other types of sensors may be used for this purpose. An unexplained reference numeral ‘50’ indicates a substrate transfer robot.
[0018] Referring to FIG. 4 , one or more grooves 22 are formed on an upper surface of the lower electrode 20 to receive respective ones of the wires 33 , when frames 31 a and 31 b are lifted down. In other embodiments, these grooves may not be formed.
[0019] FIG. 5 shows an embodiment of another type of substrate supporting apparatus. In this embodiment, supporters 31 a and 31 b are connected to each other. That is, the supporters in FIG. 3 correspond to a pair of bars but the supporters in FIG. 5 are connected to form a frame 41 . This frame may be a rectangular ring-type frame that surrounds the lower electrode. The construction and operation of shaft 42 and wires 43 may be similar to those in FIG. 3 .
[0020] Operation of the substrate supporting apparatus will now be explained with reference to FIGS. 6 a to 6 c . First, as shown in FIG. 6 a when a gate valve G is opened and a robot arm carrying a substrate S is advanced through the valve, the first and second supporters 31 a and 31 b are lifted up by the lift units. As a result, the substrate is removed from the robot arm to rest on the wires 33 as shown in FIG. 6 b.
[0021] Next, the robot arm is withdrawn through the gate valve and the first and second supporters are lowered. When the supporters are lowered, the wires are received in respective grooves formed in lower electrode 20 and substrate S is placed on the lower electrode as shown in FIG. 6 c.
[0022] Thus, one or more embodiments described herein provide a substrate supporting apparatus than can prevent spots from forming on contact portions of a substrate by using one or more wires to lift the substrate instead of lift pins.
[0023] According to one embodiment, a substrate supporting apparatus includes a pair of frames provided at both sides of a lower electrode, where the lower electrode is interposed between the frames; a plurality of shafts projected from upper surfaces of the frames; a wire whose both ends are connected to the shafts provided at both sides of the lower electrode; and a lift unit lifting up/down the frames.
[0024] A groove may be formed in an upper surface of the lower electrode to receive the wire when the frame is lifted down. The shaft may be formed integrally with the frame. Or, the shaft may be formed separately from the frame so as to be movably combined to the frame. The wire may be formed of conductor. Or, the wire may be formed of non-conductor and coated with conductor such as aluminum.
[0025] In addition, the substrate supporting apparatus may further include a sensor sensing a short of the wire to interrupt process when the wire is shorted. Both facing ends of the pair of frames may be connected with each other in a rectangular shape.
[0026] The foregoing embodiments of the substrate supporting apparatus can achieve one or more of following effects. First, the substrate is lifted using one or more wires. This prevents formation of spots on the substrate including areas that include patterns. Second, the positions of the wires can be set or changed (e.g., by moving shafts to different holes) to positions that avoid patterns on the substrate to thereby ensure that these portions of the substrate are not damaged. Third, the manufacturing process can be interrupted by quickly sensing a break (or short) in any one of the wires.
[0027] Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with other ones of the embodiments.
[0028] Although embodiments of the present invention have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this invention. More particularly, reasonable variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the foregoing disclosure, the drawings and the appended claims without departing from the spirit of the invention. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art. | 4y
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a drilling system including a drilling machine and a compressor to be connected to the drilling machine. The present invention also relates to a compressor used for a power tool such as the drilling machine.
[0002] A drilling machine for drilling holes into a structure such as a concrete wall or the like is known as disclosed in Laid-open Japanese Utility Model Application Publication No. S62-201642. The drilling machine disclosed in the JP publication includes a main body and a drill bit extending from the main body. The drill bit has a discharge port and an air passageway connected to the discharge port. The main body is also formed with an air passageway connected to the air passageway of the drill bit. The discharge port is formed in the vicinity of a cutting edge for ejecting compressed air near from the cutting edge. The air passageway in the main body of the drill machine is connected to an air outlet port of a compressor, so that the compressed air is discharged into the main body and is ejected out of the discharge port of the drill bit. Accordingly, the drill bit as well as the drilled target are cooled, and cut-out concrete dust can be discharged out of a drilled hole.
[0003] In the conventional drilling system, the rotation of a motor for rotating the drill bit and delivery of the compressed air from the compressor are not linked with each other. Therefore, an operator of the machine must adjust an air-valve provided at the main body or at the compressor in order to deliver the compressed air. Thus complicating operation results. Further, compressed air may be discharged from the discharge port even under the condition that the drilling machine has not been started up. Thus, the compressed-air has been consumed uselessly. To this effect, a large capacity compressor capable of generating greater amount of compressed air must be required taking the excessive consumption of the compressed air into consideration.
[0004] Further, in a construction site or the like in which the drilling machine is frequently used, a temporary power source is set up for allowing electric tools to be used. Since the electric power supplied from the temporary power source is lower than that supplied from a permanent power source, a frequent use of electric tools and the like that consume a large electric power may cause an overcurrent protector to be activated to render the temporary power source inoperative.
[0005] In the drilling system, each of the drilling machine and the compressor provides a driving unit requiring great amount of electric power. Thus, a simultaneous use of the drilling machine and compressor may cause the overcurrent protector to be activated to stop the supply of the power during drilling work. Further, if two driving units are operated at the same time, operational sound becomes noisy.
[0006] Further, in the case where the drilling system is used to drill holes for curtain wall anchors, holes are pierced in a sequential manner while the operator moves along the wall surface of a building. In such a case, the drilling system must also be moved. A large-sized compressor involves additional work when the compressor needs to be moved to lower workability.
[0007] Furthermore, if the drilling machine and the compressor are respectively connected to the temporary power source by means of respective power cords, a workable area is reduced to the length of the shorter power cord. Accordingly, the operator can work only the area dependent on the shorter power cord. In order to enlarge the workable area, a position of the temporary power source needs to be frequently changed. When the longer power cords are used, a workable area centered on one power source can be enlarged. However, cable handling becomes difficult to lower workability.
SUMMARY OF THE INVENTION
[0008] It is therefore, an object of the present invention to provide a compact drilling system capable of providing an improved working efficiency.
[0009] This and other objects of the present invention will be attained by an improved drilling system including a drilling machine, a compressor, a drill motor drive detection unit, and a control unit. The drilling machine includes an outer frame, a rotation shaft, and a drill motor. The outer frame defines a fluid chamber section and has a compressed fluid inlet section in communication with the fluid chamber section. The rotation shaft is rotatably supported by the outer frame and is formed with a fluid passageway in communication with the fluid chamber section. The rotation shaft has a front end to which a drilling tool is detachably attachable. The fluid passageway is opened at the front end. The drill motor is disposed in the outer frame and is drivingly connected to the rotation shaft for rotating the rotation shaft about its axis. The drilling tool has a front end provided with a cutting edge and is formed with a compressed fluid passage having one end opened to the front end for serving as a fluid ejection port and another end in communication with the fluid passageway when the drilling tool is attached to the rotation shaft. The compressor includes a compression unit, and a connection section. The compression unit generates and stores a compressed fluid. The connection section connects the compression unit to the fluid inlet section for introducing the generated compressed fluid into the rotation shaft. The drill motor drive detection unit detects a driving state of the drill motor. The control unit controls an amount of compressed fluid to be discharged from the compression unit based on the driving state of the drill motor detected by the drill motor drive detection unit.
[0010] In another aspect of the invention, there is provided a compressor including a fluid compression motor, a compressed fluid tank, a pressure detection unit, a fluid compression motor control unit, a discharge port section, and a socket. The fluid compression motor generates a compressed air. The compressed fluid tank accumulates therein the compressed fluid generated by the fluid compression motor. The pressure detection unit detects a pressure of compressed fluid accumulated in the compressed fluid tank. The fluid compression motor control unit controls the fluid compression motor based on the detection result of the pressure detection unit. The discharge port section discharges generated compressed fluid to outside. A power cord of an external power tool is electrically connectable to the socket for supplying an electric power to the power tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the drawings;
[0012] FIG. 1 is a perspective view showing an arrangement of a drilling system according to a first embodiment of the present invention;
[0013] FIG. 2 is a cross-sectional view showing a drilling machine of the drilling system according to the embodiment;
[0014] FIG. 3 is a block diagram showing a control system of the drilling system according to the embodiment;
[0015] FIG. 4 is a flowchart showing an operational routine in the drilling system according to the embodiment; and
[0016] FIG. 5 is a flowchart showing another operational routine in a drilling system according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] A drilling system according to a first embodiment of the present invention will be described with reference to FIGS. 1 through 4 . A drilling system 1 shown in FIG. 1 mainly includes a drilling machine 2 and a compressor 30 . The drilling system 1 is used for drilling shallow holes in a concrete body or the like to which screws and the like are secured. Throughout the specification, a drilling direction will be referred to as a front direction.
[0018] The drilling machine 2 shown in FIG. 2 has a housing 3 serving as an outer frame. A drill bit 22 extends from a front end of the housing 3 . A motor 4 serving as an engine for the drilling machine 2 is accommodated in the housing 3 . An output shaft 5 extends in the front direction from the motor 4 . A fan 6 for cooling the motor 4 is fixed to the output shaft 5 . A handle 7 integrally extends from a lower portion of a rear end of the housing 3 . The handle 7 is provided with a trigger 8 , and a switching circuit 9 connected to the trigger 8 is disposed within the handle 7 for controlling the rotation of the motor 4 in response to the operation of the trigger 8 . A power cord 10 connected to the switching circuit 9 extends from a lower end of the handle 7 .
[0019] A first wall 11 is positioned in front of the motor 4 and within the housing 3 to rotatably support the output shaft 5 . A second wall 12 is positioned in front of the first wall 11 and within the housing 3 . A rotation shaft 15 extends through the second wall 12 and is rotatably supported by the second wall 12 through a bearing. The second wall 12 and the bearing maintain air-tight arrangement between front and rear sides of the second wall 12 .
[0020] A first gear 13 A, an intermediate gear 13 B and a second gear 14 are disposed between the first and second walls 11 and 12 . More specifically, an intermediate shaft 25 is rotatably supported by the first and second walls 11 and 12 , and the first gear 13 A and the second gear 13 B are concentrically fixed to the intermediate gear 25 . The first gear 13 A is meshedly engaged with the output shaft 5 . The second gear 14 is concentrically fixed to the rear end portion of the rotation shaft 15 , and is meshedly engaged with the intermediate gear 13 B.
[0021] A third wall 18 is provided at the front end of the housing 3 , and a front end portion of the rotation shaft 15 frontwardly extends through the third wall 18 . The rotation shaft 15 is rotatably supported by the third wall 18 through a bearing. An airtight state is maintained between the front and rear sides of the third wall 18 and the bearing.
[0022] An air chamber 19 is defined by the housing 3 , second wall 12 , third wall 18 and output shaft 15 . An air passageway 16 is coaxially extends through a front end portion of the rotation shaft 15 , and is open at a front end face of the rotation shaft 15 . A male screw is formed at an outer peripheral surface of the front end portion of the rotation shaft 15 . An air hole 17 radially extends through the rotation shaft 15 for communication between an air chamber 19 and the air passageway 16 . Thus, the air chamber 19 is in communication with the atmosphere only through the air hole 17 and air passageway 16 .
[0023] A compressed air suction plug 20 is connected to the housing 3 at a position between the second wall 12 and third wall 18 to communicate with the air chamber 19 . An air hose 21 is attached to the compressed air suction plug 20 for supplying a compressed air. Thus, the compressed air supplied via the air hose 21 is passed through the compressed air suction plug 20 and supplied into the air chamber 19 . Then, the compressed air is passed through the air hole 17 and air passageway 16 and finally discharged to the atmosphere. The air horse 21 has a length shorter than that of the power cord 10 .
[0024] The drill bit 22 has a front end provided with a diamond cutting edge, and has a rear end portion formed with a female screw threadably engagable with the male screw of the rotation shaft 15 . An air passageway 24 is concentrically extends along an entire length of the drill bit 22 . The front end of the air passageway 24 serves as a discharge port 23 , and the rear end of the air passageway 24 is in communication with the air passageway 16 formed in the rotation shaft 15 . Thus, the compressed air supplied from the air passageway 16 is ejected out of the discharge port 23 .
[0025] The compressor 30 mainly includes a main body 31 and an air tank 32 . The main body 31 accommodates therein a control circuit 33 including a microcomputer shown in FIG. 3 . The air tank 32 stores compressed air. The compressor 30 can be easily hand-carried from one site to another in terms of its size and weight. The main body 31 includes a drill socket 37 to which the power cord 10 is connectable, a power switch 44 for the drilling machine 2 , and a compressor power cord 43 . An air discharge port 40 is formed at the main body 31 . The air hose 21 is to be coupled to the air discharge port 40 . An electromagnetic valve 38 ( FIG. 3 ) is provided in the main body 31 to serve as a valve for the air discharge port 40 . Further, an air compression motor 39 ( FIG. 3 ) is disposed in the main body 31 for generating compressed air to be stored in the air tank 32 .
[0026] As shown in FIG. 3 , the air tank 32 is provided with a pressure sensor 41 for detecting a pneumatic pressure within the tank. The drill socket 37 is provided with a current detector 42 that detects a current. The above detection results are output to the control circuit 33 .
[0027] The main body 31 further includes a drill relay 34 , a valve relay 35 and an air compression relay 36 , those connected to the control circuit 33 . Thus, these relays 34 , 35 , 36 are controlled by the control circuit 33 . The drill relay 34 is adapted to turn ON/OFF of the power supply to the drill motor 4 via the drill socket 37 . The valve relay 35 is adapted to turn ON/OFF of the power supply to the electromagnetic valve 38 . The air compression relay 36 is adapted to turn ON/OFF of the power supply to the air compression motor 39 .
[0028] In operation, the drilling operation is started with the condition shown in FIG. 1 . That is, the power cord 10 of the drilling machine 2 is connected to the drill socket 37 of the compressor 30 . The air hose 21 extending from the air discharge port 40 of the compressor 30 is connected to the compressed air suction plug 20 of the drilling machine 2 . The compressor power cord 43 of the compressor 30 is connected to a power source (not shown). In this state, an operator can perform the drilling operation within an imaginary circle centered on a power source (not shown) and having a radius corresponding to the length of the compressor power cord 43 without a need of changing the power source. In addition, the operator can perform the drilling operation within an imaginary circle centered on the compressor 30 and having a radius corresponding to the length of the air hose 21 without moving the compressor 30 . As a result, since the compressor 30 can be easily moved as described above, the operator can perform the drilling operation within a circle centered on the power source (not shown) and having a combined radius obtained by the length of the compressor power cord 43 plus the length of the air hose 21 without a need of changing the position of the power source.
[0029] The power switch 44 is turned ON in the state where the above-described connections are maintained. In this state, determination cannot be made whether compressed air has been stored in the air tank 32 , so that determination whether the drilling operation that requires the compressed air is possible or not also cannot be made. Therefore, in the initial state, the drill relay 34 , valve relay 35 , and air compression relay 36 are all in OFF state so as to disable all works and operations.
[0030] A pressure within the air tank 32 is then detected by the pressure sensor 41 . When the detected pressure is higher than a predetermined pressure, the drill relay 34 is turned ON. When the trigger 8 of the drilling machine 2 is pulled in this state, the drilling machine 2 can be activated. On the other hand, if the detected pressure is lower than the predetermined pressure, the air compression relay 36 is turned ON to activate the air compression motor 39 . A pressure within the air tank 32 is detected by the pressure sensor 41 at predetermined time intervals even in the state where the air compression motor 39 is activated. When the detected pressure becomes higher than the predetermined pressure, the air compression relay 36 is turned OFF to stop the sion relay 36 is turned OFF to stop the air compression motor 39 . Thereafter, the drill relay 34 is turned ON to allow the drilling machine 2 to be activated when the trigger 8 of the drilling machine 2 is pulled.
[0031] If the trigger 8 is pulled under the condition that the air compression relay 36 is in OFF state and the drill relay 34 is in ON state, the switching circuit 9 is turned ON to allow a current to flow into the drill motor 4 , thereby activating the drilling machine 2 . At this time, a current flow is detected by the current detector 42 provided at the drill socket 37 . Based on the detection result, the control circuit 33 turns the valve relay 35 ON to allow a current to flow into the electromagnetic valve 38 to open the air discharge port 40 . Thus, the compressed air in the air tank 32 is delivered to the air hose 21 , so that the air can be discharged out of the discharge port 23 through air passageways 16 and 24 .
[0032] A current flowing through the drill socket 37 is detected by the current detector 42 at predetermined time intervals even in the state where the drill motor 4 is activated. When the drill motor 4 is stopped and the current detector 42 detects that a current does not flow through the drill socket 37 , the control circuit 33 turns the valve relay 35 OFF to stop the discharge of compressed air. Thereafter, a pressure within the air tank 32 is again detected by the pressure sensor 41 . When the detected pressure is not greater than the predetermined pressure, the air compression relay 36 is turned ON after the drill relay 34 has been turned OFF, so that compressed air is stored in the air tank 32 by the air compression motor 39 . At the time when a pressure within the air tank 32 becomes higher than the predetermined pressure, the air compression relay 36 is turned OFF. The drill relay 34 is then turned ON to start the drilling operation. By repeating the above process, the drilling operation can be performed continuously.
[0033] The above process will be described based on a flowchart shown in FIG. 4 . Firstly, the power switch 44 is turned ON as a starting condition. The routine then advances to S 01 . In S 01 , initial setting is performed, that is, confirmation is made that the drill relay 34 , valve relay 35 , and air compression relay 36 are all in OFF state. After the confirmation, the routine proceeds into S 02 where a pressure within the air tank 32 is detected.
[0034] Based on the detection result in S 02 , determination is made in S 03 whether the pressure within the air tank 32 is higher than the predetermined pressure. When it has been determined that the pressure is not more than the predetermined pressure (S 03 :No), the routine advances to S 04 . In S 04 , the drill relay 34 is turned OFF. At the start time, since all the relays have been turned OFF in S 01 , the drill relay 34 is maintained in OFF state without change. The air compression relay 36 is then turned ON in S 05 to activate the air compression motor 39 , thereby storing compressed air in the air tank 32 . Thereafter, the routine returns to S 02 , where a pressure within the air tank 32 is again detected. A flow A including S 02 to S 05 is repeated until a pressure within the air tank 32 has become higher than the predetermined pressure.
[0035] In S 03 , when the pressure within the air tank 32 is determined to be higher than the predetermined pressure (S 03 :Yes), the routine advances to S 06 where the air compression relay 36 is turned OFF to stop the air compression motor 39 . After that, the routine advances to S 07 where the drill relay 34 is turned ON to make the drill motor 4 ready for operation.
[0036] At the time when the drill motor 4 is in ready condition, the routine advances to S 08 , where a current flowing through the drill socket 37 is detected. Based on the detection result, determination is made in S 09 whether a current flows or not, in other words, determination whether the drilling operation of the drilling machine 2 is being performed by the operator or not is made. When it has been determined that the drilling operation is being performed (S 09 :Yes), the routine advances to S 11 where the valve relay 35 is turned ON to open the electromagnetic valve 38 , so that the compressed air is discharged from the air discharge port 40 into the drilling machine 2 . Thereafter, the routine returns to S 08 where a current flowing through the drill socket 37 is again detected. While the drilling machine 2 is operated, a flow C including S 08 , S 09 , and S 11 is repeated.
[0037] When the determination is made in S 09 that the drilling operation is not being performed, that is, a current does not flow through the drill socket 37 (S 09 :No), the routine advances to S 10 where the valve relay 35 is turned OFF. Thereafter, the routine returns to S 02 . In S 02 , a pressure within the air tank 32 is again detected. In S 03 , when the pressure within the air tank 32 is determined to be not greater than the predetermined pressure, the routine advances to S 04 , where the air compression relay 36 is turned ON after the drill relay 34 has been turned OFF. After that, the routine returns to S 02 . While the drilling machine 2 is not operated, a flow B including S 02 , S 03 , and S 06 to S 10 is repeated.
[0038] A drilling system according to a second embodiment of the present invention will be described with reference to a flowchart shown in FIG. 5 . The second embodiment is similar to the first embodiment in terms of a mechanical arrangement. An operational routine S 1 through S 11 is the same as that of S 101 to S 111 of the second embodiment. However, the second embodiment further includes steps S 111 through S 115 because of the following reason. Since deep hole drilling is not assumed in the drilling system 1 according to the above embodiment, the case where a pressure within the air tank 32 falls below the predetermined pressure during drilling operation is not paid attention to. Thus, as a modification to the first embodiment, the flowchart shown in FIG. 5 includes the case where a pressure within the air tank 32 falls below the predetermined pressure during drilling operation. In the flowchart of FIG. 5 , since the routine from S 101 to S 111 is the same as the routine from S 01 to S 11 in the flowchart of FIG. 4 , the description thereof will be omitted.
[0039] After the valve relay 35 has been turned ON in S 111 , a pressure within the air tank 32 is detected in S 112 . Based on the detection result, determination is made in S 113 whether the pressure within the air tank 32 is greater than a specified value that is sufficient for cooling the drill bit 2 . When the pressure within the air tank 32 is determined to be higher than the specified value (S 113 :Yes), the routine returns to S 108 . When the pressure within the air tank 32 is determined to be not greater than the specified value (S 113 :No), the routine advances to S 114 , where the drill relay 34 is turned OFF. After that, the routine advances to S 115 where the air compression relay 36 is turned OFF to end the operation. If the drilling system 1 is to be operated again, the routine will be started from S 101 .
[0040] According to the above-described embodiments, compressed fluid can automatically be supplied from the compressor 30 to the drilling machine 2 only at the time when the drilling machine 2 is operated, and an amount of the compressed fluid to be supplied can be adjusted depending on the operational state of the drilling machine 2 .
[0041] Further, since the drill motor 4 and air compression motor 39 , which are the driving units that consume the most electric power, are not operated simultaneously, maximum electric power consumption can be reduced, and reduced noise generation can result.
[0042] Further, the compressed air is not wastefully consumed in the compressor 30 , a satisfactory cooling effect can be expected in spite of an employment of a compact compressor.
[0043] While the invention has been described in detail and with reference to specific embodiments thereof, it would be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit and scope of the invention. For example, in the above-described embodiments, whether the drilling machine 2 is running or not is confirmed by detection to the current flowing through the drill socket 37 . Alternatively, however, the operation of the drilling machine 2 may be confirmed based on a voltage change, vibration of the drilling machine 2 , noise or the like. | 4y
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BACKGROUND OF THE INVENTION
The invention relates to a superconducting composite conductor with stabilizing material and several superconducting conductor strands which consist of an intermetallic compound developed in a diffusion reaction of at least two elements and are embedded in a normally-conducting matrix which is surrounded by an aluminum jacket and contains copper as the alloying component of at least one of the elements of the compound, where at least one alloying element of the matrix is separated by a barrier from the stabilizing material. Composite superconducting conductors are known, for instance, from "IEEE Transactions on Magnetics", Vol. MAG-19 No. 3, May 1983, pages 672 to 675. The invention further relates to a method for manufacturing such a composite superconducting conductor. Superconductors suited for technical applications always contain in addition to a superconducting material component a normally-conducting component of high conductivity for stabilizing the superconducting state. If a local temperature rise occurs in such a conductor, for instance, as a result of jumps in the flux, the current-carrying capacity of the superconductor is reduced in the region under discussion or disappears altogether indeed, but the current can be carried for a brief moment by the normally-conducting component, so that the superconductor has the opportunity to recover. This process is therefore also designated as a stabilization means against transient disturbances. With the stabilizing component an excessive temperature rise of a coil wound with such a superconductor and its possible destruction can therefore be prevented.
For stabilizing superconductors, high-conductivity copper (Cu) is generally used which, with a so-called external stabilization, surrounds the superconductor in the form of a jacket, or, in the case of a so-called internal stabilization, is arranged as at least one core in the center of the conductor. Besides copper, aluminum (Al) is gaining increasing importance as a normally-conducting component for the stabilization of superconductors.
The conductivity of aluminum as compared with that of copper is substantially higher at 4.2° K. in a space free of magnetic field and also decreases considerably less in a magnetic field with increasing flux density than the conductivity of Cu. Thus, at 4,2° K. resistivities of 2×10 -9 ohm-cm and 6×10 -10 ohm-cm, respectively, are measured on samples of soft-annealed Cu 99.997% and soft-annealed Al 99.995%. At 4.2° K. and with a magnetic flux density of 12 tesla, the resistivity of copper samples is about 26/times higher that of aluminum samples, but only 6/times higher than in the absence of a magnetic field.
Such composite superconducting conductors, the current-carrying component of which is a brittle, nondeformable intermetallic compound, can be produced particularly by a special method, the so-called bronze process. In the case of the intermetallic compound Nb 3 Sn, prefabricated composite wires with the final dimensions of the desired conductor, consisting of niobium wires or filaments in a matrix of copper-tin bronze are annealed at a temperature of about 700° C. for a predetermined time. Tin dissolved in copper, where in general in the phase, reacts in a solid reaction with the niobium, forming the desired intermetallic compound Nb 3 Sn. If such bronze conductors are stabilized, as customary, with copper, the bronze of the matrix and the copper of the stabilizing cross section must be separated by a special intermediate layer, for instance, of niobium or in particular, of tantatum. Such metals then act as a diffusion barrier (see, for instance, DE-OS No. 23 39 525) and prevent, during the annealing reaction to develop the desired super-conducting compound, the penetration of tin into the stabilizing copper and thereby resulting in a reduction of the latter's electric and thermal conductivity. Admixtures as small as 0.05% by weight of tin reduce the residual resistance ratio of copper from about 1,000 to a value of about 20. With electrically and therefore also thermally poorly conducting copper, however, a sufficient stabilizing effect on the superconducting state is not attainable.
Next to copper as the stabilizing material of such composite conductors, stabilization with aluminum is also known. For this purpose the aluminum can be soldered, after the reaction, on a twisted conductor by means of lead-tin solder (see, "IEEE Transactions on Magnetics", Vol. MAG-17, No. 5, September 1981, pages 2047 to 2050).
Composite conductors of bronze and niobium filaments with a central core of aluminum can also be fabricated, where this core is surrounded by a diffusion barrier of niobium (see, for instance, "IEEE Transactions on Magnetics", Vol. MAG-21, No. 2, March 1985, pages 157 to 160). With this conductor type, however, the annealing reaction must be carried out below the melting point of aluminum.
Another method for stabilizing a superconductor composite conductor with aluminum is found in the publication mentioned at the outset "IEEE Trans. Magn." Vol. MAG-19. According to this method, a preliminary conductor product is first fabricated by embedding a predetermined number of wires of the one element of the compound, especially niobium wires, in a matrix which contains the remaining element or elements of the compound in the form of an alloy and thus consists of a tin-bronze, for instance. In addition, this structure contains, particularly on its outside, also copper as the stabilizing material which is separated from the bronze material in a manner known per se by diffusion-retarding or -inhibitory barriers. After this structure is worked to the desired final form, the desired superconducting compound such as Nb 3 Sn is developed in a diffusion reaction by means of a heat treatment. The superconducting core is finally provided with an aluminum jacket by extrusion; a good metallurgical bond between the copper and the aluminum can be achieved in this manner.
With the superconducting composite conductors produced by this known method, the diffusion barriers thus require part of the normal-conducting cross section, so that in this conductor type the effective current density J ov is limited accordingly. Furthermore the cross section cannot be reduced arbitrarily since the niobium or tantalum tubes used as barrier material have a tendency to burst if their wall thickness is too small, as would occur with the usual high degrees of deformation of the raw conductors.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to develop a superconducting composite conductor of the type mentioned at the outset in such a way that it can be stabilized by aluminum in a technically simple and cost-saving manner, and at the same time an effective current density J ov as high as possible is assured.
According to the invention, this problem is solved by the provision that the barrier is formed by the common boundary layer or interface between the aluminum of the jacket and the copper of the matrix alloy, and consists of at least one intermetallic copper-aluminum compound. A boundary layer is understood here to be also a transition region consisting of several layer-like or laminate zones between the mentioned metals.
The invention starts out from the fact that after the diffusion reaction for developing the desired superconducting intermetallic compound, the one element of this compound, which was at first present in the form of an alloy in the matrix, is not consumed completely but is still present in the matrix even though in a small amount. It is the basis of the invention that the matrix material can be provided with an aluminum jacket directly without adversely affecting the stabilizing action to an appreciable degree. For, in the process step of jacketing the matrix with aluminum, which must be carried out at elevated temperature, several Cu-Al compounds are generally developed by a diffusion reaction at the boundary layer between the copper of the alloying matrix and the aluminum of the jacket, which act as a barrier for the element of the superconducting compound still present in the matrix. In the case of a tin bronze, the still present tin does not diffuse through this boundary layer and therefore does not penetrate the aluminum. The advantages achieved with the invention are in particular that specific diffusion barriers such as of niobium or tantalum can be dispensed with and also a separate external copper layer of the matrix is not necessary. The superconducting conductor according to the invention is therefore of simple design and can be produced at low cost accordingly.
It is particularly advantageous to produce the superconducting composite conductor according to the invention by forming a conductor core with superconducting conductor filaments embedded in the matrix by a so-called bronze process and providing this conductor core subsequently, by extrusion at elevated temperature, with the aluminum jacket, the boundary layer being produced concurrently.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further explanation of the invention, reference is made in the following to the drawings wherein like parts are identified by like reference numerals.
FIGS. 1 and 2 show schematically a cross section through the structure of a composite superconducting conductor according to the invention.
FIG. 3 shows a detail of the composite conductor according to FIG. 2.
FIG. 4 shows schematically a further embodiment of a composite conductor according to the invention.
In the figures, like parts are provided with the same reference symbols.
DETAILED DESCRIPTION OF THE INVENTION
The embodiment examples indicated in the figures are based on producing composite superconducting conductors, and superconducting material of which is a superconducting intermetallic compound of the type A 3 B consisting of two components with at least one element each, which compound has an A15 crystal structure. The compound Nb 3 Sn will be assumed to be the material, although other binary or tertiary compounds can be produced similarly just as well. Since these compounds are generally very brittle, it is difficult to produce them in a form suitable, for instance, for magnet coils. For manufacturing them, the so-called bronze technique is therefore used (see, for instance, DE-OS No. 2,056,779; "Cryogenics", June 1976, pages 323 to 330 or "Kerntechnik", Vol. 20, 1978, No. 6, pages 253 to 261). This known method serves particularly for manufacturing so-called multicore conductors with conductor filaments arranged in a normal-conducting matrix (i.e. a matrix which is normally conductive at operating temperature of the superconducting material) which have at least superficial layers of the compounds mentioned. For this purpose a ductile element, for instance, in wire form of the compound to be produced is first surrounded by means of a compound containing ductile material of the matrix in a predetermined amount of the other elements of the compound to be made in the form of an alloy. A multiplicity of such wires can also be embedded in the matrix. The structure so obtained in then subjected to a cross section-reducing process and cut into a predetermined number of sections. These sections are then bundled and again elongated by reducing their cross section. By the reductions of the cross section, the diameter of the wire cores is reduced to a small value in the order of several millimeters. Thus, a not yet fully reacted preliminary product of the superconducting composite conductor is obtained in the proposed form of a long wire such as required for winding coils. This preliminary product is finally subjected to an annealing treatment in a vacuum or the atmosphere of an inert gas such as argon, where the element or elements contained in the matrix, of the superconducting alloy to be formed, diffuse into the material of the wire cores consisting of the other element of the compound and thus react with the latter, forming a layer consisting of the desired superconducting compound.
According to the embodiment example of a composite conductor 2 shown in FIG. 1, a conductor core 3 with circular cross section is thus obtained which contains a multiplicity of superconducting conductors or filaments 4 which are embedded in the matrix 5. The conductor filaments 4 consists here, at least at their surface, of the intermetallic compound Nb 3 Sn. The matrix, for which initially an α-bronze with a maximum tin content of about 14.5% by weight is used as a lease for ductility reasons, still has left a residue of tin of several percent by weight even after the annealing treatment for forming the superconducting intermetallic compound. It consists therefore of a bronze as before with a substantially reduced tin content of, for instance, 3% by weight. According to the invention it is particularly easy and also cost-saving to stabilize this bronze matrix 5 with the embedded Nb 3 Sn conductors 4 with aluminum while preserving an effective current density J ov as large as possible. To this end, the conductor core 3 which is advantageously present in a monolithic form (i.e., a single conductor core 3 is within jacket 6 as illustrated, e.g., in FIG. 1), is jacketed in a manner known per se by extrusion with aluminum after the annealing reaction at a temperature between about 400° and 550° C. and preferably between 450° and 500° C. which is optimum for the current-carrying capacity. In the process, also the desired final profile of the composite conductor is formed.
Deviating from the presentation according to FIG. 1, this final profile may also be, for instance, rectangular. A corresponding cross section of such a rectangular conductor 8 is indicated in FIG. 2. In this figure the deformed matrix is designated by 5' and the deformed aluminum jacket by 6'. Between these parts, the boundary layer 9 is formed which acts as a barrier between the aluminum and the tin found in the bronze of the matrix 5. A portion of this boundary layer 9 is shown magnified in FIG. 3.
The structure of the boundary layer 9 shown in this figure between the bronze matrix 5' and the aluminum jacket 6' can be detected by specific diffusion tests. It has been found that the large residual resistivity ratio of pure aluminum is not reduced practically if aluminum, pressed on bronze CuSn 3 is annealed for no longer than 0.5 hour at 500° C. A decrease of the aluminum conductivity in the extrusion process which occurs substantially faster is therefore not expected. A bronze with 3% by weight tin (CuSn 3 ) is assumed here since this concentration occurs frequently in the matrix bronze of reaction-annealed Nb 3 Sn conductors. Macroscopic examination and x-ray microanalyses of corresponding diffusion samples show that layers or zones, of few micrometers thick, of various intermetallic Cu-Al compounds are formed at the phase boundaries CuSn 3 /Al with short annealing times. According to FIG. 3, the boundary layer 9 between the matrix 5' and the jacket 6' formed after an anneal of one-ahlf hour at 500° C. is composed of three layer-like or laminal zones 9a, 9b, 9c with the respective thicknesses da, db and dc. The zone 9a with a thickness da of about 1 micrometer adjoining the matrix 5' consists here of an δ-phase (delta phase) of the system Cu-Al, while the material of the intermediate zone of about the same thickness, 9b, represents a η-phase (eta phase) of this system. For the zone 9c with a thickness dc of about 1.5 micrometers adjoining the Al jacket 6', a υ-phase (upsilon phase) of the mentioned system Cu-Al can be determined. The phase designations are chosen here in compliance with the teachings of M. Hansen and K. Anderko in "Constitution of Binary Alloys", McGraw Hill Book Company, New York 1958. Because of this formation of the layer-like zones 9a to 9c, a good bond between the material of the matrix 5' containing the superconducting conductor filaments 4 and the stabilizing aluminum jacket 6' is assured. Furthermore, it is clear that a transport of matter takes place exclusively by migration of the copper atoms. Accordingly, no aluminum is found in the bronze of the matrix 5' and conversely, no tin is found in the aluminum of the jacket 6'.
On the basis of this metallurgical process Nb 3 Sn superconductors which are pre-reacted by means of the described extrusion process and which consist only of a bronze matrix and embedded Nb 3 Sn conductor filaments can be stabilized by aluminum without the incorporation of additional diffusion barriers. The amount of nonsuperconducting material in the conductor cross section is thereby minimized, differing from stabilization by Cu clad with Ta tantalum. Thus, correspondingly higher values for the effective current density J ov are obtained.
In the manufacture of the composite conductors 2 and 8 shown in FIGS. 1 to 3, a matrix was assumed which has an at least largely homogenous composition of its bronze. It is particularly advantageous, however, if individual regions 13 with greater tin content are additionally provided in this matrix in order to reduce tin diffusion paths during the annealing reaction for developing the desired superconducting compound. Such an embodiment example is the basis of the composite conductor which is indicated in FIG. 4 and designated with 11. This composite conductor corresponds largely to the conductor 2 shown in FIG. 1 and thus has a circular cross section, although it could have just as well the profile shown in FIG. 2. Its central conductor core 12 is provided with an aluminum jacket 6 after diffusion annealing. In this core, a region 13 is formed, however, which came from a subarea of the bronze matrix which was filled with tin (Sn) before the annealing reaction and with which several percent by weight (generally up to about 10% by weight) copper (Cu) can be alloyed. Since not all the Sn is used up during the annealing treatment a certain excess of Sn is still present in the region 13 shown. Instead of the one region with an excess of Sn, also several Sn(Cu) regions uniformly distributed over the cross section of the conductor core can advantageously be provided.
In addition, conductor corres of composite conductors can, of course, be surrounded with aluminum, differing from the embodiment examples shown in the figures, in the bronze matrix of which regions of Cu surrounded by special diffusion barriers are arranged, in addition to the superconducting conductor filaments. The type and design of the diffusion layers 9a to 9c between the outer Al jacket 6 or 6' and the adjoining material of the bronze matrix 5 or 5' do not change, since the tin does not participate in the reaction process at the boundary region between these materials. This can also be seen from the fact that in diffusion samples which are annealed for several hours at 500° C., even a considerable rise of the tin concentration is observed which is a consequence of the Cu migration into the Al. | 4y
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BACKGROUND
1. Field of Invention
This invention relates to bedding anchors and is particularly directed to apparatus for anchoring the sides of bedsheets and the like to prevent wrinkling or dislocation of the sheet by a person occupying the bed.
2. Prior Art
In hospitals, rest homes and the like, where patients spend considerable periods of time in bed and, often, are unable to leave the bed for more that a short period of time, if at all, the problem of sheet wrinkles can become a major concern, causing great discomfort to the patients and tending to cause skin irritation and to create bed sores which can become infected and, hence, may lead to serious complications. Unfortunately, no matter how tightly the sheets are drawn, during the process of making the bed, movement of the patient will, eventually, cause some loosening of the sheet and, thereby will create wrinkles. Obviously, it is impractical to provide continual attention for every patient, so that the sheets can be retightened whenever wrinkles occur. However, even when such constant attention is possible, as with full-time private nursing, some wrinkling invariably occurs.
Numerous devices have been proposed, heretofore, to overcome these difficulties. However, many of the prior art bedding anchors have served only to retain the corners of the bedding which aids in preventing dislocation of the sheets, but does little to prevent wrinkles. Other prior art bedding anchors have been provided inadequate gripping and, hence, have tended to slip and become ineffective. Still other prior art bedding anchors have been expensive to purchase and complicated to use. Again, some prior art bedding anchors have been effective when a patient is relatively quiet, but tend to become loosened when the patient is unsually restless. A search in the United States Patent Office has revealed the following references:
______________________________________U.S. PAT. NO. INVENTOR ISSUED______________________________________2,931,084 H. K. De Witt Apr. 5, 19602,988,759 V. E. Gerdes Jun. 20, 19613,092,848 G. B. Gronvold Jun. 11, 19634,276,667 B. C. Osbourne Jul. 7, 1981______________________________________
Each of these patents is subject to the objections noted above. Thus, none of the prior art bedding anchors have been entirely satisfactory.
BRIEF SUMMARY AND OBJECTS OF INVENTION
These disadvantages of prior art bedding anchors are overcome and improved bedding anchors are provided which are inexpensive to produce and purchase and which are simple to install, yet which serve to securely retain the edge of a sheet and, hence, to prevent wrinkles, even when the occupant of the bed is extremely restless.
The advantages of the present invention are preferably attained by providing an improved bedding anchor comprising a first member having a generally T-shaped slot formed therein to receive a portion of the edge of a sheet, a cylindrical retaining member, an anchor member engageable with a fixed portion of the bed, and elastic means securing said first member to said anchor member.
Accordingly, it is an object of the present invention to provide an improved bedding anchor.
Another object of the present invention is to provide an improved bedding anchor which is inexpensive to purchase and simple to install.
A further object of the present invention is to provide an improved bedding anchor which serves to securely retain the edge of a sheet and, hence, to prevent wrinkles, even when the occupant of the bed is extremely restless.
A specific object of the present invention is to provide an improved bedding anchor comprising a first member having a generally T-shaped slot formed therein to receive a portion of the edge of a sheet, a cylindrical retaining member, an anchor member engageable with a fixed portion of the bed, and elastic means securing said first member to said anchor member.
These and other objects and features of the present invention will be apparent from the following detailed description, taken with reference to the figures of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front view of a bedding anchor embodying the present invention;
FIG. 2 is a side view of the bedding anchor of FIG. 1;
FIG. 3 is a diagrammatic view showing the bedding anchor of FIG. 1 being employed to anchor a sheet;
FIG. 4 is a side view of an alternative form of the anchor portion of the bedding anchor of FIG. 1; and
FIG. 5 is a side view of a further alternative form of the anchor portion of the bedding anchor of FIG. 1 for use with water beds.
DETAILED DESCRIPTION OF THE INVENTION
In that form of the present invention chosen for purposes of illustration in FIG. 1, a bedding anchor is shown, indicated generally at 10, having an upper member 12 formed with a generally T-shaped opening 14, a generally cylindrical retaining member 16 and a tined anchor member 18 joined to the upper member 12 by a flexible member 20, such as a bungee cord. As shown, the anchor member 18 is formed with two outer legs 22 and 24 and a central leg 26 which is laterally offset from the plane of the outer legs 22 and 24, as indicated at 28. However, it will be apparent that, if desired, the anchor member 18 could be formed with a single leg. The upper member 12, retaining member 16 and anchor member 18 are preferably formed of relatively rigid material, such as wood, metal or rigid plastic and the retaining member 16 may be either tubular, as shown or a solid cylinder, as desired.
In use, the anchor member 18 is hooked onto the frame 30 of a bed, adjacent a support 32 for a bed spring 34 or the like. A loop 36 of sheet 38 adjacent the lower edge 40 is drawn through the T-shaped opening 14 of upper member 12 and the retaining member 16 is inserted into the loop 36, as seen in FIG. 3. Since, as seen in FIG. 1, the retaining member 16 is larger than the T-shaped opening 14, the retaining member 16 prevents the loop 36 of sheet 38 from being withdrawn through the opening 14 and, hence, since the upper member 12 is attached to the anchor member 18 by the flexible member 20, the bedding anchor 10 serves to retain the lower edge 40 of the sheet 38 in a desired position. If the patient moves about in the bed in a manner to pull on the sheet 38, the flexible member 20 will allow the edge 40 of the sheet 38 to move accordingly. However, the flexible member 20 will cause the upper member 12 and retaining member 16 to maintain tension on the edge 40 of the sheet 38, so that if the patient moves in a manner to relieve the stress on the sheet 38, the flexible member 20 will automatically adjust for this by pulling on the upper member 12 and, hence, on the lop 36 of the sheet 38 to assure that tension is constantly maintained on the sheet 38 so that the sheet 38 does not become limp and wrinkles are prevented. It is preferred that a plurality, three, for example, of the bedding anchors 10 be applied along each side of a bed to provide more uniform tension on the sheet 38 and, hence, to more completely prevent wrinkles.
FIG. 4 shows an alternative form of the anchor member 18 of the bedding anchor 10 for use with metal beds. In this form of the invention, the anchor member 18 is formed with a generally J-shaped hook portion 42, which may or may not be tined. The generally J-shaped hook portion 42 facilitates attachment to bed frames having rounded configurations, such as are found in metal beds. Similarly, FIG. 5 shows a further alternative form of the anchor member 18 which is flat, as seen at 44 in FIG. 5. This form of the anchor member 18 is intended for use in anchoring bedding on a water bed or the like having a frame with no openings which would accommodate hook-type anchor members 18, such as those of FIGS. 1-4.
Obviously, numerous other variations and modifications can be made without departing from the spirit of the present invention. Therefore, it should be clearly understood that the forms of the present invention described above and shown in the figures of the accompanying drawings are illustrative only and are not intended to limit the scope of the present invention. | 4y
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FIELD OF THE INVENTION
The present invention relates to a novel therapeutic application of riluzole (6-trifluoro-methoxy-2-aminobenzothiazole) or the pharmaceutically acceptable salts of this compound.
BACKGROUND OF THE INVENTION
Riluzole is useful as an anticonvulsant, anxiolytic and hypnotic medicinal product (Patent EP 50,551), in the treatment of schizophrenia (EP 305,276), in the treatment of sleep disorders and depression (EP 305,277), in the treatment of cerebrovascular disorders and as an anaesthetic (EP 282,971).
DESCRIPTION OF THE INVENTION
It has now been found, surprisingly, that this compound may also be used to promote restoration following radiation.
Restoration following radiation is useful in X-ray therapy, in particular in the treatment of cancers, and against other sources of harmful radiation such as those encountered by persons in areas in the vicinity of nuclear explosions.
EXAMPLES
The activity of the product has been demonstrated on the rhinencephalon of young rats subjected to an overall gamma irradiation.
Irradiation is performed by means of a gamma ray source, cobalt-60.
The animals used are 15-day-old male Sprague-Dawley strain rats weighing 28 to 33 g, which are placed in an aerated Plexiglass restraining box undergoing a rotation of 180° in order to carry out homogeneous overall irradiations in a single dose of 1.5 and 2.5 Gy, the dose rate of which is 0.2 Gy per minute. The survival time between irradiation and sacrifice is 6 hours. All the animals are fixed by intra-aortic perfusion of a fixative fluid composed of 1% of paraformaldehyde, 1% of glutaraldehyde and 0.05% of calcium chloride in 0.4M phosphate buffer, pH 7.3. To prevent coagulation, 0.04 ml of heparin is injected into the ventricle, and 0.3 ml of 1% sodium nitrite to clear the vessels of red cells.
The animals are anaesthetized by intraperitoneal injection of 3% pentobarbitone sodium. The animals are then laid on their back and fixed to the operating table. The thoracic cage is opened and held open by means of 2 clamps. The heart is thus exposed, the tip of the left ventricle is incised and the perfusion cannula is introduced up to the beginning of the arch of the aorta and clamped. The right atrium is incised and perfusion is performed. Inflow of the perfusion fluid is effected under gravity. After perfusion, the animal's head is cut off and the brain is removed, immersed in fixative fluid and stored overnight at 4° C.
On the day following perfusion, frontal sections of the gyrus dentatus are cut under a binocular magnifier. The fragments collected are immersed in the washing fluid for 5 minutes. They are then dehydrated in alcohol baths of increasing concentration and thereafter included in Araldite. 1-micrometer semi-thin sections are prepared using a Reichert ultramicrotome with glass knives. They are stained in the heated state with a filtered 1% solution of toluidine blue prepared in 1% borate buffer, and then observed using an Orthoplan microscope.
The comparative study consists in counting on 3 non-serial sections (separated by 10 micrometers each) for each rat and on an aggregate of 1000 cells (granular and subgranular) in total. The number of pyknotic cells is counted, and then the number of surviving cells observed in this area. This enables the percentage of surviving cells relative to the number of cells in the area to be calculated (percentage survival=100×living cells/living cells+pyknotic cells).
The product under study is administered intraperitoneally at doses of 1, 2, 4 and 8 mg/kg, 20 minutes after irradiation (at the beginning of pyknosis).
The results obtained are recorded in the following tables, and show that, after treatment with the test product, neuronal degeneration is less than in irradiated controls not receiving a product.
TEST 1______________________________________IR- CONTROLS RILUZOLE (2 mg/kg)RADIATION CELLULAR SURVIVAL CELLULAR SURVIVAL______________________________________1.5 Gy 88.8% 91.2%2.5 Gy 87.1% 92.2%______________________________________
TEST 2__________________________________________________________________________ RILUZOLE RILUZOLE RILUZOLE RILUZOLE CONTROLS 1 mg/kg 2 mg/kg 4 mg/kg 8 mg/kg CELLULAR CELLULAR CELLULAR CELLULAR CELLULARIRRADIATION SURVIVAL SURVIVAL SURVIVAL SURVIVAL SURVIVAL__________________________________________________________________________2.5 Gy 75.35 ± 2.4% 81.99 ± 2.32% 83.54 ± 1.96% 86.07 ± 2.78 85.41 ± 2.14%__________________________________________________________________________
As pharmaceutically acceptable salts, the addition salts with inorganic acids, such as hydrochloride, sulphate, nitrate or phosphate, or organic acids, such as acetate, propionate, succinate, oxalate, benzoate, fumarate, maleate, methanesulphonate, isethionate, theophyllineacetate, salicylate, phenolphthalinate or methylenebis(β-hydroxynaphthoate), or substitution derivatives of these derivatives, may be mentioned in particular.
The medicinal products consist at least of riluzole, in free form or in the form of an addition salt with a pharmaceutically acceptable acid, in the pure state or in the form of a composition in which it is combined with any other pharmaceutically compatible product, which may be inert or physiologically active. The medicinal products according to the invention may be employed orally or parenterally.
As solid compositions for oral administration, tablets, pills, powders (gelatin capsules, wafer capsules) or granules may be used. In these compositions, the active principle according to the invention is mixed with one or more inert diluents such as starch, cellulose, sucrose, lactose or silica, under a stream of argon. These compositions can also comprise substances other than diluents, for example one or more lubricants such as magnesium stearate or talc, a colouring, a coating (dragees) or a varnish.
As liquid compositions for oral administration, pharmaceutically acceptable solutions, suspensions, emulsions, syrups and elixirs may be used, containing inert diluents such as water, ethanol, glycerol, vegetable oils or liquid paraffin. These compositions can comprise substances other than diluents, for example wetting, sweetening, thickening, flavouring or stabilizing products.
The sterile compositions for parenteral administration can preferably be solutions, aqueous or non-aqueous, suspensions or emulsions. As a solvent or vehicle, water, propylene glycol, a polyethylene glycol, vegetable oils, especially olive oil, injectable organic esters, for example ethyl oleate, or other suitable organic solvents may be employed. These compositions can also contain adjuvants, especially wetting, tonicity, emulsifying, dispersing and stabilizing agents. The sterilization may be carried out in several ways, for example by aseptic filtration, by incorporation of sterilizing agents in the composition, by irradiation or by heating. They may also be prepared in the form of sterile solid compositions which can be dissolved at the time of use in sterile water or any other sterile injectable medium.
The doses depend on the effect sought, the treatment period and the administration route used; they are generally between 50 and 800 mg per day via the oral route for an adult, with single doses ranging from 25 to 200 mg of active substance, and between 25 and 600 mg per day via the intravenous route for an adult, with single doses ranging from 12.5 to 200 mg of active substance.
Generally speaking, the doctor will determine the appropriate dosage in accordance with the age, the weight and all other factors specific to the subject to be treated.
The examples which follow illustrate medicinal products according to the invention:
EXAMPLE A
Tablets containing a 50 mg dose of active product and having the following composition are prepared according to the usual technique:
______________________________________Riluzole 50 mgMannitol 64 mgMicrocrystalline cellulose 50 mgPovidone excipient 12 mgSodium carboxymethylstarch 16 mgTalc 4 mgMagnesium stearate 2 mgColloidal silica, anhydrous 2 mgMixture of methylhydroxypropyl-cellulose, polyethylene glycol6000 and titanium dioxide(72:3.5:24.5)q.s. 1 finished film-coated tabletweighing 245 mg______________________________________
EXAMPLE B
Hard gelatin capsules containing a 50 mg dose of active product and having the following composition are prepared according to the usual technique:
______________________________________Riluzole 50 mgCellulose 18 mgLactose 55 mgColloidal silica 1 mgSodium carboxymethylstarch 10 mgTalc 10 mgMagnesium stearate 1 mg______________________________________
EXAMPLE C
An injection containing 10 mg of active product and having the following composition is prepared:
______________________________________Riluzole 10 mgBenzoic acid 80 mgBenzyl alcohol 0.06 cm.sup.3Sodium benzoate 80 mgEthanol, 95% 0.4 cm.sup.3Sodium hydroxide 24 mgPropylene glycol 1.6 cm.sup.3Water q.s. 4 cm.sup.3______________________________________
The invention also relates to the process for preparing medicinal products which can be used to promote restoration following radiation, consisting in mixing riluzole or the pharmaceutically acceptable salts of this compound with one or more compatible and pharmaceutically acceptable diluents and/or adjuvants.
The invention also relates to a method for treating a mammal, and in particular man, requiring restoration following radiation, comprising the administration of an effective amount of riluzole or the pharmaceutically acceptable salts of this compound.
Although the invention has been described in conjunction with specific embodiments, it is evident that many alternatives and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the invention is intended to embrace all of the alternatives and variations that fall within the spirit and scope of the appended claims. The above references are hereby incorporated by reference. | 4y
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TECHNICAL FIELD
The present invention pertains to connecting rods for internal combustion engines and the like. In particular, the invention pertains to a connecting rod, having split bearing bosses disposed at its longitudinal ends for a piston pin and a crankpin, which includes two rod components essentially arranged on opposite sides of a central longitudinal plane defined by the bearing axes of the two bearing bosses, and wherein the rod components include extensions overlapping each other and the central plane and arranged one behind the other in the direction of the bearing axes with bores extending in the direction of the bearing axes.
BACKGROUND
A connecting rod of the type described above is disclosed as the embodiment of FIGS. 4 and 5 in German patent No. 658,462. This prior art connecting rod comprises two rod components joined along a longitudinal dividing plane and having ends designed to receive a piston pin and a crankpin. The rod components have U-shaped cross sections, the backs of which butt against each other at their ends adjacent to the piston pin bearing and to the crankpin bearing and are secured by connecting means.
The connecting means at the crankpin end comprise extensions of the side flanges of the U-shaped sections of each rod component. The extensions overlap the central plane and are provided with holes so that, after assembly of the rod components, the extension means are located one on top of another and can be connected to each other by a pin or bolt. In addition, one connecting means each is provided on either side, longitudinally, of the piston pin bearing at the piston pin end of the connecting rod. These two connecting means are shown as threaded bolts with nuts whose axes are disposed perpendicular to the central plane and, thus, perpendicular to the direction of the bearing axis. The threaded bolts at the piston pin end may also be replaced by two connecting means which correspond to those located at the crankpin end. Due to the form of the connecting means, the prior art connecting rod is expensive to manufacture and difficult to mount.
A two part connecting rod in which hemispherical protrusions are provided instead of a VL bearing boss for the piston pin is also disclosed in International Patent Application No. WO 86/04122. These protrusions are cast integral with the rod components and form bearings for a piston by engaging in the piston spherical segments of a matching shape. To insert the hemispherical protrusions into the spherical segments, the top part of the prior art connecting rod, which can be connected to the piston, is split in a dividing plane extending perpendicular to the bearing axis, while the dividing plane in the lower part of the connecting rod extends in the usual manner in the direction of the bearing axis. Furthermore, the top ends of the two rod components are beveled on their inner sides such that a wedge-shaped space is formed which permits the protrusions to be inserted into the spherical segments of the piston. The spherical segment-type bearing for the piston, which determines the type of assembly and consequently the shape of the prior art connecting rod, considerably restricts the use of this connecting rod.
SUMMARY OF THE INVENTION
The present invention provides a connecting rod which consists of a small number of parts, can be manufactured at low cost and can be mounted in a simple manner.
This is accomplished according to the present invention in that the dividing plane of one of the two bearing bosses, preferably that of the bearing boss associated with the piston pin, extends perpendicular to its bearing axis, wherein the bearing boss is formed by extensions of the two rod components overlapping the center plane, while the other bearing boss, preferably that associated with the crankpin, has a dividing plane passing through (incorporating) the bearing axis. Due to the crosswise (perpendicular to the bearing axis) division of the (e.g. piston pin) bearing boss, the components of this bearing--the two bearing boss halves and the pin passing through the bearing boss halves--can be assembled in a hinged manner. No additional connecting means are needed in the assembled state to hold together the components of this bearing. The separate connecting means needed for this bearing in the prior art connecting rod are thus eliminated in an advantageous manner, which leads to a substantial weight reduction and permits manufacture at a lower cost. In addition, the second order forces of inertia and the engine vibrations are reduced.
Due to the dividing plane of the piston pin bearing boss preferably extending perpendicular to the bearing axis and the resulting elimination of additional connecting means on the piston pin bearing, boss, simultaneous closure of the crankpin bearing split along the bearing boss axis, will not necessarily take place during the assembly of the piston pin bearing. The mounting of the connecting rod on the piston pin and on the crankpin can be carried out in separate steps in an extremely advantageous manner.
According to the present invention, the (e.g. piston pin) bearing with the bearing bosses split perpendicular to the bearing axis, which are formed by extensions of the rod components, is first assembled by pushing the pin member into the bores. The two rod components are then pivoted out or unfolded around this bearing axis in a tong-like manner and the other (e.g. crankpin) bearing member is then introduced between the spaced halves of the other (axially split) bearing boss, the rod components are pivoted or folded together, and the two parts of the axially split bearing boss are fastened to each other. Thus, the piston pin can advantageously first be introduced into the two haves of the crosswise divided bearing boss and mounted in the piston with the connecting rod attached. Due to the hinged design of this bearing, the two rod components can be unfolded in a tong-like manner, which considerably simplifies the mounting to the crankshaft crankpin. In addition, perfect symmetry of the two rod components is also possible. As a consequence of this, only one die is needed to manufacture same.
In an advantageous variant of the present invention, additional extensions are provided having bores for receiving at least one additional pin, preferably on the outer end of the crankpin bearing boss. This design permits an extremely simple connection of the two rod components, since the pin or pins must simply be inserted into the bores. The arrangement of the pin axis or axes in parallel to the bearing axes leads to an especially compact design of the crankpin bearing boss and to an especially small connecting rod enveloping curve, which permits a compact design of the crankcase. This design also leads to an additional weight reduction. This variant also makes it possible to make the two rod components perfectly symmetrical to each other, so that only one die will be needed in this case as well. Perfect symmetry is also achieved during the other treatments of the rod components, especially in terms of the bores for receiving an additional pin. A known threaded bolt, the other end of which is secured with a nut, can be used as a pin for connecting the two rod components.
A variant in which the pin (pins) is (are) designed as threaded bolts and in which one of the associated extensions on the two rod components has a through hole and the other has a threaded hole for the threaded bolt is especially advantageous. This offers the advantage that commercially available multipoint recessed head cap screws, e.g., Inner Torx, can be substituted for special, heavier and more complicated connecting rod screws or pin connections.
An embodiment in which extensions having bores for receiving two threaded bolts, essentially located along the central longitudinal plane of the connecting rod, are provided on both sides of the bearing for the crankpin, is advantageous in terms of the simplification of the connecting components and in view of the stocking of spare parts.
The present invention also offers favorable possibilities for assembly in that bores for receiving threaded bolts, which are preferably centrally disposed in the transverse direction of the connecting rod and essentially extend perpendicular to the dividing plane through the axis of the crankpin bearing, may be provided in the rod components on both sides of the crankpin bearing. This design is particularly favorable for manufacture since the machining of the dividing surfaces and of the bores can be carried out in one machine setup. This is also true of another variant in which bores for receiving a pin, preferably a threaded bolt, are provided in the rod components on the side of the crankpin bearing toward the piston pin bearing, and are preferably centrally disposed in the transverse direction of the connecting rod and essentially extend perpendicular to the dividing plane through the axis of the crankpin bearing, and in which extensions of the rod components on the side of the crankpin bearing away from the piston pin bearing are provided with bores for an additional pin, preferably a threaded bolt. This also leads to a compact design of the connecting rod and a small connecting rod enveloping curve, as well as a compact crankcase. In addition to light weight and low second order forces of inertia, the friction of the piston, the wear on the cylinder liner, as well as the fuel consumption, will be reduced.
Assembly may be facilitated by inclination of the dividing plane through the axis of the crankpin bearing relative to the central longitudinal plane.
Various embodiments of the present invention are shown in the drawings and will be explained below in greater detail.
DRAWING DESCRIPTION
In the drawings:
FIG. 1 shows a plan view of the connecting rod;
FIG. 2 shows a side view of the connecting rod of FIG. 1
FIG. 3 shows the two rod components of the connecting rod of FIG. 1;
Figure a sectional view along the line 4--4 of FIG. 1;
FIG. 5 shows the connecting rod with the rod components in a partially assembled position;
FIG. 6 shows an alternative embodiment of the lower rod eye;
FIG. 7 shows a side view of the connecting rod eye according FIG. 6;
FIG. 8 shows another embodiment of the lower connecting rod eye;
FIG. 9 shows alternative detail of the piston pin end of the connecting rod, and
FIG. 10 shows a sectional view along the line 10--10 in FIG. 9.
Identical parts are designated by identical reference numerals in the figures.
DETAILED DESCRIPTION
Referring now to the drawings in detail, the connecting rod 1 has a central longitudinal axis 1a and comprises two rod components 2 and 3 which can be connected to each other by threaded bolts 4 and 5 in the form of threaded screws with Torx multipoint recessed head cap screws. At its upper longitudinal end in FIG. 1, the connecting rod has a piston pin bearing boss 6 with a bearing 7 centered on an axis 7a for receiving a piston pin (not shown) and, at its lower end, it has a crankpin bearing boss 8 with a bearing 9 centered on an axis 9a for receiving the crankpin (likewise not shown) of a crankshaft. The two bearing bosses 6 and 8 are connected to each other by webs 10 and 11. The extension of the webs 10 and 11 in the transverse direction defined by the direction of the bearing axes 7a, 9a is somewhat smaller than that of the bearing bosses 6 and 8.
The bearing bosses 6 and 8 are split. The piston pin bearing boss 6 is split along a dividing plane 12 which passes perpendicular to the bearing axis 7a and centrally relative to the transverse extension of the webs 10 and 11 and of the bearing boss 6. The boss 6 comprises two hollow cylindrical segments 15 and 16, each associated with one of the rod components 2 and 3. The crankpin bearing boss 8 is split along a dividing plane 13 which extends through the bearing axis 9a and the longitudinal axis la of the connecting rod 1. The plane 13 divides the bearing boss 8 axially and longitudinally into left and right lateral halves 17 and 18, which are associated with the rod components 2 and 3, respectively, and are disposed on opposite sides of a central longitudinal plane 1b defined by the axes of the bearings 7 and 9 and coextensive with the dividing plane 13.
As is clearly apparent from FIG. 3, the rod component 2 carries the left lateral half 17 of the bearing 9 as well as the hollow cylindrical segment 15 of bearing 7 which includes an extension 21 that overlaps the central plant 1b by half. Analogously, the rod component 3 includes an extension 22 which forms the part of the hollow cylindrical segment 16 which overlaps the central plane 1b by half. Rod component 3 also carries the right longitudinal half 18 of the bearing 9. The two longitudinal bearing halves 17 and 18 correspond to the dimension of the bearing boss 8 in the axial direction. The two hollow cylindrical segments 15 and 16 are arranged coaxially, one behind the other in the direction of the bearing axis and each forms a half of the upper bearing boss 6.
In the zone of the bearing boss 6, the webs 10 and 11 are provided with clearance spaces extending in the transverse direction between the webs 10, 11 and the extensions 22, 21 of the opposite rod components 3, 2, respectively. For example, clearance space 19, located between the web 10 and the extension 22, is shown in FIGS. 1 and 2. The clearance spaces extend to the center of the web in the axial direction and somewhat further than the outer radius of the bearing boss 6--starting from its center--in the radial direction. Thus, they permit the two hollow cylindrical segments 15 and 16 of the bearing boss 6 to butt against each other and to be rotated relative to one another.
The webs 10 and 11 are spaced from the central plane lb of the connecting rod 1 to define an opening 20 between them in the assembled state of the connecting rod 1.
The rod component 2 has two additional extensions 23 and 25 of semicircular cross section which overlap the central plane. These extensions form parts of round fastening eyes 27 and 28 which overlap the central plane 1b. In FIG. 3, these parts are adjacent the far end of the bearing boss 8 and are provided with threaded holes 31.
Analogously, the rod component 3 has two additional extensions 24 and 26 of semicircular cross section which overlap the central plane and form parts of the round fastening eyes 27 an 28. In FIG. 3, these parts are adjacent the near end of the bearing boss 8 and are provided with through holes 32.
As is especially apparent from FIG. 4, the extensions 23 and 24 as well as 25 and 26 are arranged one behind the other in the direction of the bearing axes and they overlap each other in the mounted state of the connecting rod 1. They are held in contact with each other by threaded bolts 4, 5 in the form of Torx multipoint recessed head cap screws which are inserted into the holes. With contact surfaces 29 extending in a transverse central plane of the connecting rod 1, the extensions 21, 23 and 25 of the rod component 2 abut contact surfaces 30 of the extensions 22, 24 and 26 of the rod component 3.
The connection of the connecting rod with a piston (not shown) and the crankpin of a crankshaft (also not shown) will be explained below on the basis of FIG. 5. As is shown in FIG. 3, the rod components 2 and 3 are associated with each other, and the extensions 21 and 22 are overlapped to form the bearing boss 6 with the holes in the extensions 21 and 22 aligned with each other to form the bearing 7. The piston pin is inserted into the bearing 7 to connect it with an associated piston.
The two rod components 2 and 3, which can be pivoted around the bearing axis fixed by the piston pin are now pivoted out or unfolded in a tong-like manner by rotating at least one of the rod components 2 and 3 until they assume the position shown in FIG. 5 in the unfolded or opened state. The two lateral halves 17 and 18 of the hollow cylinder or bearing boss 8 forming the bearing 9 are thus spaced from each other an amount sufficient for introducing the crankpin. The assembly unit formed by the piston the piston pin and the rod components 2 and 3 is pushed for this purpose into the cylinder bore associated with the piston until a predetermined assembly position is reached. With the rod components folded together, the connecting rod can be pushed through the cylindrical bore from the top, which means that the bearing boss 8 can be pushed through the entire cylinder bore. Once the connecting rod with the bearing boss 8 has been completely pushed through the cylindrical bore, so that the rod components with the bearing boss 8 project from the cylinder bore at the bottom, the rod components can again be pivoted apart or unfolded so that the crankpin of the crankshaft can be introduced into the bearing 9. The unfolded rod components 2 and 3 are then folded together. In the folded-together state, the bearing 9 is closed and the threaded holes 31 and the through holes 32 are aligned with each other, so that the two threaded bolts 4 and 5 can be screwed in to hold the rod components 2 and 3 in contact with each other.
A modified embodiment of connecting means associated with the bearing boss 8 on the crankpin end is shown in FIGS. 6 and 7. Unlike in the above-described design, the axes of the threaded bolts extend perpendicular to the longitudinal plane 1b of the connecting rod 1 rather than in the direction of the axis of the bearing 9 in the center plane. stepped holes, which have, beginning from the dividing plane 13, a cylindrical section 62 and an adjoining threaded hole 61, are provided in the rod component 2; the cylindrical section 62 has the same diameter as the through hole 63 in the rod component 3. The threaded bolts 65 are designed as fit screws.
FIG. 8 shows an embodiment of the bearing boss 8 in which the dividing plane 13 receiving the bearing axis is inclined by an angle a relative to the central plane 1b defined by the axes 7a, 9a of the bearings 7 and 9. The dividing plane is inclined 7° from the central plane in the example. This bearing boss 8 otherwise corresponds to the above-described design shown in FIGS. 6 and 7.
FIGS. 9 and 10 show a connecting means for the two rod components 2 and 3 which is, in principle, of the same design and orientation as the connecting means shown in FIG. 4 and described above. A tongue-shaped extension 93 with a semicircular end section extends from the web 10 in a transverse plane. This extension overlaps the center plane between the two webs 10 and 11, while a tongue-shaped extension 94, which also overlaps the center plane with a semicircular end section, extends from the web 11. In FIG. 9, the extension 94 is located on the near side of the extension 93 in the transverse direction. The extension 93 has a threaded hole 96 and the extension 94 has a through hole 97, the two holes extending in the same direction (transverse direction) as the axis of the piston pin bearing 7. A Torx multipoint recessed head cap screw is provided as the threaded bolt 95. After folding up or closing the rod components 2 and 3, the threaded bolt 95 is screwed into the threaded hole 93. The connecting means shown is arranged next to the piston pin bearing boss 6 and may be provided, in addition to the connecting means, with the threaded bolts 4,5 (FIGS. 1 through 5) and 5 (FIGS. 6 through 8), which are arranged next to the bearing boss 8.
In an embodiment which is not shown, the two connecting means associated with the crankpin bearing 9 can be designed such that the lower of the two connecting means is arranged like the lower connecting means on the crankpin bearing 9 in FIGS. 1 through 5, while the upper of the two connecting means is arranged like the upper connecting means on the crankpin bearing 9 in FIGS. 6 and 7.
It is also possible to additionally provide connecting means according to FIGS. 9 and 10 The dividing plane 13 of the crankpin bearing 9 may also be inclined.
While the invention has been described by reference to certain preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described Accordingly it is intended that the invention not be limited to the disclosed embodiments, but that it have the full scope permitted by the language of the following claims. | 4y
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TECHNICAL FIELD
[0001] The present invention relates to a wireless communication system and, more particularly, to a base station device and a handover control method, which perform handover control.
BACKGROUND ART
[0002] As one of measures to improve a system throughput in a cellular network, there is a technique of arranging a plurality of small base-station devices in a macrocell provided by a base station device. Because an area of a small cell provided by the small base-station device is small, a mobile terminal device is not necessarily present in the small cell. Accordingly, in a state in which no mobile terminal device is present in the small cell, electric power consumed by the small base-station device is wasted. Thus, in 3GPP (3rd Generation Partnership Project), Energy Saving function is proposed as one of SON (Self Organization Networks) functions (NPTL1).
[0003] A small base-station device having the Energy Saving function has an active state and an inactive state. In the active state, such device performs a normal operation as the small base-station device. In the inactive state, power saving of the entire network is realized by stopping radio transmission in a part or the whole of the cells. The state-transition of the active state/inactive state of the cell can be controlled according to a traffic amount. For example, based on statistical data of traffic change, the number of the small base-station devices in operation is increased in a time zone, such as a traffic peak time, in which the traffic amount is large. In a time zone, such as an off-peak time, in which the traffic amount is small, the number of the small base-station devices in operation is reduced.
[0004] However, the stopping of the radio transmission may have a large impact on the mobile terminal device and neighboring cells. Thus, when an own cell transfers to an inactive state, specification of a signal notifying the neighboring cell of the transition of the own cell to an inactive state is performed as specific processing for reducing the impact. In addition, a signal requesting an inactive cell to become active is specified (NPTL2). The notification and request messages are usually transmitted via an inter-base-station interface between the base station devices which control target cells.
[0005] Furthermore, in a mobile communication system having a plurality of base station devices like a cellular network, mobility control or handover control is performed, which switches base stations so that communication is continued when a mobile terminal device moves from a cell provided one of the base station devices to another cell provided by another of the base station devices. Handover of the mobile terminal device is controlled, based on a value measured and reported by the mobile terminal device, by the base station device providing a cell in whichthe mobile terminal device is located. Generally, the base station device controls the handover to select a better cell (or best cell) in respect of radio wave reception environment for the mobile terminal device and to hand over the mobile terminal to the selected cell.
[0006] Hereinafter, a general handover control procedure is briefly described with reference to FIG. 1 . Incidentally, a cell in which a mobile terminal device is present is referred to as a serving cell. A base station device of a serving cell is referred to as a serving base station device. A handover destination cell is referred to as a target cell. A base station device of a target cell is referred to as a target base station device.
[0007] In FIG. 1 , a serving base station device sets measurement conditions, measurement reporting conditions, and the like by transmitting a measurement setting message M 100 to a mobile terminal device. The mobile terminal device measures reference signal received power (RSRP: Reference Signal Received Power), reference signal received quality (RSRQ: Reference Signal Received Quality), or other parameters of each of the serving cell and the neighboring cell according to the measurement conditions set by the serving base station device (operation S 100 ). The parameters includes reference signal received power (RSRP: Reference Signal Received Power), reference signal received quality (RSRQ: Reference Signal Received Quality), or other parameters. Then, if a measurement result satisfies the measurement reporting conditions, a measurement reporting message M 101 is transmitted to the serving base station device.
[0008] The serving base station device performs handover execution determination, based on a measurement report received from the mobile terminal device (operation S 101 ). In the handover execution determination, a target cell is determined by judging whether handover execution is necessary. In the determination of a target cell, generally, a cell is selected, which is better in radio wave reception environment for the mobile terminal device. Subsequently, the serving base station device transmits, when the target cell is determined, a handover request message M 102 including information concerning the mobile terminal device to the target base station device.
[0009] The target base station device performs, upon the handover request received from the serving base station device, judging of acceptance of a mobile terminal device (operation S 102 ). The judging of acceptance is performed, based on access control rules such as access authority of the mobile terminal device and a load of the target base station device. If the mobile terminal device is determined to be acceptable, handover preparation such as securement of data resources for the mobile terminal device is executed. Then, if handover is determined to be acceptable, the target base station device transmits, to the serving base station device, a handover request response message M 103 including a handover instruction to the mobile terminal device.
[0010] Upon the handover request response, the serving base station device transmits, to the mobile terminal device, a handover instruction message M 104 received from the target base station device. In response to the handover instruction, the mobile terminal device transmits a handover instruction response to the target base station device. Thus, the handover control procedure is completed.
[0011] Incidentally, a method is proposed, which determines, when a target base station is determined, a preferential order by considering not only quality of the radio wave reception environment but capability of the neighboring base station (see PTL1).
CITATION LIST
Patent Literature
[0000]
[PTL1] Japanese Patent Application Laid-Open No. 2011-525759
Non-Patent Literatures
[0000]
[NPTL1] 3GPP TS36.300, Evolved Universal Terrestrial Radio Access (E-UTRA) and Evolved Universal Terrestrial Radio Access Network; Overall description; Stage 2, V10.2.0
[NPTL2] 3GPP TS36.423, Evolved Universal Terrestrial Radio Access Network (E-UTRAN); X2 Application Protocol (X2AP), V9.2.0
SUMMARY OF INVENTION
Technical Problem
[0015] However, when a base station device makes an inactive cell of a small base-station device transfer to an active state, radio wave reception environment of the activated cell may be better for a mobile terminal device being present in vicinity of the activated cell than radio wave reception environment of the serving cell. When many such mobile terminal devices are present, many mobile terminal devices are simultaneously handed over to the small base-station device by the handover control. Generally, the small base-station device is low in processing capability, compared to the base station device. Thus, increase in local processing load has a high probability of causing a congestion state of the small base-station. Consequently, there is a problem that service quality is degraded due to a handover failure and a processing delay.
[0016] Accordingly, an object of the present invention is to provide a base station device and a handover control method capable of avoiding, when a cell transfers from an inactive state to an active state, a situation in which a base station device of the cell is overloaded.
Solution to Problem
[0017] A base station device according to the present invention is a base station device in a wireless communication system, which includes a neighboring base station information storage means that stores neighboring base station information including handover inhibition information associated with a neighboring cell managed by a neighboring base station device, and a processing capability index of the neighboring base station device, and a handover control means that limits that, when the neighboring cell transfers from an inactive state to an active state, a mobile terminal device hands over to the activated neighboring cell, based on the handover inhibition information and the processing capability index.
[0018] A handover control method according to the present invention is a handover control method in a wireless communication system, which includes storing neighboring base station information including handover inhibition information associated with a neighboring cell managed by a neighboring base station device, and a processing capability index of the neighboring base station device, and limiting that, when the neighboring cell transitions from an inactive state to an active state, a mobile terminal hands over to the activated neighboring cell, based on the handover inhibition information and the processing capability index.
Advantageous Effects of Invention
[0019] According to the present invention, when a neighboring cell is activated, handover of a mobile terminal device which communicates with a serving base station to the neighboring cell is limited. Thus, a situation can be avoided, in which a base station device of the neighboring cell is overloaded.
BRIEF DESCRIPTION OF DRAWINGS
[0020] FIG. 1 is a sequence diagram illustrating a general handover control procedure.
[0021] FIG. 2 is a schematic diagram illustrating a schematic configuration of a wireless communication system according to a first exemplary embodiment of the present invention.
[0022] FIG. 3 is a block diagram illustrating a configuration of a base station device according to the present exemplary embodiment.
[0023] FIG. 4 is a schematic diagram illustrating an example of a neighboring base station information table in the present exemplary embodiment.
[0024] FIG. 5 is a sequence diagram illustrating a handover control procedure according to the present exemplary embodiment.
[0025] FIG. 6 is a flowchart illustrating a handover control operation of a base station device according to the present exemplary embodiment.
[0026] FIG. 7 is a schematic diagram illustrating a schematic configuration of a wireless communication system according to a second exemplary embodiment of the present invention.
[0027] FIG. 8 is a sequence diagram illustrating a handover control procedure according to the present exemplary embodiment.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0028] According to exemplary embodiments of the present invention, a base station device acquires a processing capability index of a neighboring base station device by inter-base-station communication. When the base station device detects that a cell of the neighboring base station device transfers from an inactive state to an active state, the base station device inhibits handover of a mobile terminal device to the activated cell, based on the processing capability index of the neighboring base station device, for a specified period of time. Consequently, increase in processing-load of the neighboring base station can be suppressed. Even a small base-station device with low processing capability can avoid a congestion state due to overload. Hereinafter, exemplary embodiments of the present invention are described in detail with reference to the drawings.
1. First Exemplary Embodiment
1. 1) System Configuration
[0029] In FIG. 2 , in order not to complicate description, it is assumed that a wireless communication system according to a first exemplary embodiment is configured by a base station device 100 , a small base-station device 200 , and a mobile terminal device 300 , and that the base station device 100 and the small base-station device 200 are connected via an inter-base-station interface to each other. Here, a cell configuration is illustrated, in which a small cell 200 a of the small base-station device 200 is included in a macrocell 100 a of the base station device 100 . However, the present exemplary embodiment is not limited thereto. Incidentally, the small cell 200 a may be either a picocell or a microcell. Additionally, the base station device 100 and the small base-station device 200 may be connected to another base station device (not illustrated) via an inter-base-station interface. Hereinafter, a case where the base station device 100 makes an inactive cell of the small base-station device 200 transition to an active state is described as an example.
1. 2) Base Station Device
[0030] As illustrated in FIG. 3 , the base station device 100 is configured by a wireless communication control unit 110 , an inter-base-station communication control unit 120 , a handover control unit 130 , an activation control unit 140 , and a neighboring base station device information table 150 . However, here, for simplicity of drawing, only a configuration relating to the present exemplary embodiment is illustrated. The base station device 100 has a control unit equivalent to a base station device used in a general mobile communication system.
[0031] The wireless communication control unit 110 is connected to a mobile terminal device via a wireless link, and performs data transmission and reception therewith. The inter-base-station communication control unit 120 establishes an inter-base-station interface with the neighboring base station device, and performs data transmission and reception with the neighboring base station device via the established inter-base-station interface. The handover control unit 130 executes handover execution determination and handover control, based on a measurement report from the mobile terminal device.
[0032] The activation control unit 140 determines whether to activate the inactive cell 200 a of the small base-station device 200 under the macrocell 100 a of the base station device 100 . Whether to activate the inactive cell 200 a can be determined, based on statistical traffic information in the macrocell 100 a . For example, in a traffic-peak time, the inactive cell is controlled to transfer to an active cell.
[0033] As illustrated in FIG. 4 , the neighboring base station information table 150 has a neighboring base station device ID concerning each of neighboring base station devices neighboring the base station device 100 , neighboring cell information concerning a cell of each of the neighboring base station devices, surrounding cell information concerning cells located around the cell of each of the neighboring base station devices, handover inhibition timer information associated with each neighboring cell, the number of times of executing handover to the neighboring cell during the handover inhibition timer is being activated, and information concerning a processing capability index of each of the neighboring base station devices. Information concerning a cell of the neighboring base station device, neighboring cell information concerning a cell of the neighboring base station device, and information concerning the processing capability index of the neighboring base station device are recorded, based on information received when the inter-base-station interface is established.
[0034] The handover timer information represents information indicating whether the handover inhibition timer is being activated (ON) or stopped (OFF), and an elapsed time if the timer is being activated. For example, in a cell C 1 a of a neighboring base station BS 1 illustrated in FIG. 4 , the handover inhibition timer is activated, and the elapsed time is T 1 a.
[0035] The processing capability index is the number of processable calls per second, or the like. Additionally, the number of times of executing handover represents the number of times of executing, during the handover inhibition timer is being activated, handover processing from the cell 100 a of the base station device 100 to the neighboring cell (here, the cell 200 a ).
[0036] Incidentally, functions of the inter-base-station communication control unit 120 , the handover control unit 130 , and the activation control unit 140 can be implemented by executing programs stored in a memory (not illustrated) on a computer (CPU: Central Processing Unit).
[0037] 1. 3) Handover Inhibition Control
[0038] In FIG. 5 , first, the base station device 100 and the small base-station device 200 establish an inter-base-station interface by exchanging an inter-base-station interface establishment request message M 200 and a response message M 201 thereto. The inter-base-station interface establishment request message M 200 and the response message M 201 thereto include cell information concerning cells of the base station devices respectively transmitting these messages, neighboring cell information concerning cells of the neighboring base station devices respectively transmitting these messages, and information concerning a processing capability index of each of relevant neighboring base station devices. In the present exemplary embodiment, the base station device transmits the inter-base-station interface establishment request message M 200 , and the small base-station device transmits the response message M 201 . However, this may be vice versa.
[0039] The inter-base-station control unit 120 of the base station device 100 extracts the above information from the response message M 201 received from the small base-station device 200 and records the extracted information in a neighboring base station device information table 150 (operation S 200 ). Next, if it is determined (operation S 201 ) that an inactive cell of the small base-station device 200 is activated, the activation control unit 140 of the base station device 100 transmits a cell activation request message M 202 to the small base-station device 200 .
[0040] The small base-station device 200 activates a cell designated in the cell activation request message M 202 (operation S 202 ) and transmits a cell activation request response message M 203 to the base station device 100 after the cell is activated. Incidentally, in the present exemplary embodiment, the small base-station device 200 transmits the inter-base-station interface establishment response message M 201 in which the neighboring cell information concerning the cell of the small base-station device 200 and the processing capability index of the small base-station device 200 are included. However, the small base-station device 200 may transmit the cell activation request response message M 203 in which the neighboring cell information concerning the cell of the small base-station device 200 and the processing capability index of the small base-station device 200 are included. In this case, an operation S 200 of the base station device 100 is performed after the base station device 100 receives the cell activation request response message M 203 .
[0041] When the base station device 100 receives the cell activation request response message M 203 , the handover control unit 130 of the base station device 100 activates a handover inhibition timer associated with the activated designated-cell of the small base-station device 200 (operation S 203 ). When the handover inhibition timer is activated, the handover inhibition timer information in the neighboring base station device information table 150 is updated to ON.
[0042] If the handover inhibition timer is being activated, the handover control unit 130 inhibits the handover control conditionally, as is described below, even when receiving a measurement report message M 204 from the mobile terminal device 300 (operation S 204 ). Then, when the handover inhibition timer stops after elapse of a predetermined period of time, the handover control unit 130 updates the handover inhibition timer information in the relevant cell in the neighboring base station device information table 150 from ON to OFF, and initializes the number of times of executing handover (i.e., sets the number of times of executing handover to 0) (operation S 205 ).
[0043] Hereinafter, the handover inhibition control operation S 204 in the base station device 100 according to the present exemplary embodiment is described with reference to FIG. 6 .
[0044] In FIG. 6 , when the wireless communication control unit 110 of the base station device 100 receives the measurement report message M 204 from the mobile terminal device 300 , the handover control unit 130 determines, based on the received measurement report, a handover destination candidate cell (operation S 300 ). Handover destination candidate cell determination processing can select, e.g., all of neighboring cells, each of which is larger in reference signal received power than the serving cell, as the candidate cells. Hereinafter, the handover destination candidate cells are assumed to be determined, based on the reference signal received power. However, a technique of determining a handover destination cell according to a measurement report value other than the received power may be employed.
[0045] Next, the handover control unit 130 selects a cell (best cell), which is largest in reference signal received power, from the selected handover destination candidate cells and refers to the neighboring base station device information table 150 . Thus the handover control unit 130 determines whether the handover inhibition timer is being activated in the best cell (operation S 301 ). If the handover inhibition timer is being activated (operation S 301 ; YES), the handover control unit 130 acquires cell information concerning the best cell from the neighboring base station device information table 150 (operation S 302 ). The cell information includes the processing capability index of the neighboring base station device (here, the small base-station device 200 ) controlling the cell concerned, the number of neighboring cells, and the number of times of executing handover thereto.
[0046] Next, the handover control unit 130 determines whether a value (actual result value) obtained by dividing a number calculated by adding 1 to the number of times of executing handover included in the acquired cell information by a handover inhibition timer elapsed time is smaller than a value (capability threshold) obtained by dividing the processing capability index by the number of the neighboring cells (operation S 303 ).
[0047] If the actual result value is less than the capability threshold (operation S 303 ; YES), the handover control unit 130 can determine that the processing capability of the neighboring base station device has a margin. Therefore, the handover control unit 130 determines the best cell as a handover destination cell (operation S 304 ) and increments the number of times of executing handover of the best cell in the neighboring base station device information table 150 by 1 .
[0048] If the actual result value is equal to or more than the capability threshold (operation S 303 ; NO), the processing capability of the neighboring base station device of the best cell has no margin. Thus, the handover control unit 130 determines whether there is still another cell among the selected handover destination candidate cells (operation S 305 ). If there is still another cell (operation S 305 ; YES), the handover control unit 130 excludes, from the handover destination candidate cells, the cell of the neighboring base station device concerned (operation S 306 ). Then, the handover control unit 130 returns to the above operation S 301 . If there are no other cells (operation S 305 ; NO), the handover control unit 130 inhibits handover to the mobile terminal device 300 to the best cell (operation S 307 ).
[0049] Incidentally, if the handover inhibition timer associated with the best cell is being stopped (operation S 301 ; NO), as normal, the handover control unit 130 determines the best cell as a handover destination cell (operation S 308 ). Thus, when the handover destination cell is determined, handover processing is executed as described with reference to FIG. 1 .
1. 4) Advantageous Effects
[0050] As described above, according to the first exemplary embodiment of the present invention, when a cell of the neighboring small base-station device 200 transitions from an inactive state to an active state, handover of the mobile terminal device 300 to the activated cell 200 a is inhibited, based on the processing capability index of the small base-station device 200 , for a certain period of time until the inhibition timer is timed out. Consequently, rapid increase in processing-load of the small base-station device 200 can be avoided. Degradation of service quality due to a handover failure and a processing delay can be reduced.
2. Second Exemplary Embodiment
2. 1) System Configuration
[0051] In FIG. 7 , in order not to complicate description, it is assumed that a wireless communication system according to a second exemplary embodiment is configured by base station devices 100 and 101 , a small base-station device 200 , and mobile terminal devices 300 and 301 , and that each of the base station devices 100 and 101 is connected to the small base-station device 200 via an inter-base-station interface. Here, a cell configuration is illustrated, in which a small cell 200 a of the small base-station device 200 is provided in a peripheral portion where a macrocell 100 a of the base station device 100 overlaps a macrocell 101 a of the base station device 101 . However, the present exemplary embodiment is not limited thereto. It is assumed that the mobile terminal device 300 is located in the cell 100 a of the base station device 100 , and that the mobile terminal device 301 is located in the cell 101 a of the base station device 101 . Hereinafter, a case where the base station device 100 makes an inactive cell of the small base-station device 200 transition to an active state is described as an example.
2. 2) Base Station Device
[0052] The base station devices 100 and 101 each have a configuration similar to the block configuration illustrated in FIG. 3 . Therefore, description of the base station devices 100 and 101 is omitted.
2. 3) Handover Inhibition Control
[0053] In a sequence diagram illustrated in FIG. 8 , a same operation as that in the handover inhibition control procedure according to the first exemplary embodiment illustrated in FIG. 5 is designated with same reference numeral. Therefore, description of such an operation is omitted. Only different operations in the procedure are described.
[0054] As already described, similarly to the procedure in which the base station device 100 and the small base-station device 200 establish the inter-base-station interface, the base station device 101 and the small base-station device 200 establish the inter-base-station interface by exchanging an inter-base-station interface establishment request message M 200 and a response message M 201 thereto. Then, the base station devices 100 and 101 extract the above information from the response message M 201 received from the small base-station device 200 and records the extracted information on a neighboring base station device information table 150 (operation S 200 ). In addition, as described above, the inter-base-station interface establishment request message M 200 and the response message M 201 thereto include cell information concerning cells located under the transmitting-side base station devices, neighboring cell information concerning cells respectively the neighboring cells of the transmitting-side base station devices, and information concerning a processing capability index of each of relevant neighboring base station devices. As a specific processing capability index, the number of processable calls per second is set.
[0055] The small base-station device 200 activates a designated cell according to the cell activation request message M 202 received from the base station device 100 (operation S 202 ). After the activation of the cell, the small base-station device 200 transmits a cell activation request response message M 203 and a cell state change notification message M 205 to the base station devices 100 and 101 , respectively. Incidentally, even in the present exemplary embodiment, similarly to the first exemplary embodiment, the neighboring cell information, and information concerning the processing capability index may be transmitted by being included in each of the cell activation request response message M 203 and the cell state change notification message M 205 . In this case, the operation S 200 of each of the base station devices 100 and 101 is performed after an associated one of the cell activation request response message M 203 and the cell state change notification message M 205 is received.
[0056] When the base station devices 100 and 101 receive the cell activation request response message M 203 and the cell state change notification message M 205 , respectively, a handover inhibition timer associated with the designated cell activated by the small base-station device 200 is activated (operation S 203 ). When the handover inhibition timer is activated, handover inhibition timer information in a neighboring base station device information table 150 of each of the base station devices 100 and 101 is updated to ON.
[0057] If the handover inhibition timer is being activated, the base station device 100 inhibits the handover control conditionally, as already described, even when receiving a measurement report message M 204 from the mobile terminal device 300 . Similarly, the base station device 101 inhibits the handover control conditionally, even when receiving a measurement report message M 204 from the mobile terminal device 301 (operation S 204 ). Then, when the handover inhibition timer stops after elapse of a predetermined period of time, each of the base station devices 100 and 101 updates the handover inhibition timer information in the relevant cell in the neighboring base station device information table 150 from ON to OFF, and initializes the number (=0) of times of executing handover (operation S 205 ). The handover inhibition control operation S 204 of the base station device 101 is similar to that of the base station device 100 described with reference to FIG. 6 . Therefore, description of the handover inhibition control operation S 204 of the base station device 101 is omitted.
3. Supplemental Notes
[0058] A part or all of the above exemplary embodiments can also be described as the following supplemental notes. However, the present invention is not limited thereto.
[Supplemental Note 1]
[0059] A base station device in a wireless communication system, including:
[0060] a neighboring base station information storage means which stores neighboring base station information including handover inhibition information associated with a neighboring cell managed by a neighboring base station device, and a processing capability index of the neighboring base station device; and
[0061] a handover control means which limits, when the neighboring cell transitions from an inactive state to an active state, handover to the activated neighboring cell of a subordinate mobile terminal device, based on the handover inhibition information and the processing capability index.
[Supplemental Note 2]
[0062] The base station device according to Supplemental Note 1, in which the handover inhibition information is a handover inhibition timer that is activated when the neighboring cell transitions from an inactive state to an active state, and that indicates a predetermined handover inhibition time, and in which the handover control means inhibits, during the handover inhibition time, handover of the mobile terminal device to the neighboring cell, based on the processing capability index.
[Supplemental Note 3]
[0063] The base station device according to Supplemental Note 2, in which the handover control means permits handover of the mobile terminal device to the neighboring cell only in a case where the processing capability of the neighboring base station device has a margin, if within the handover inhibition time.
[Supplemental Note 4]
[0064] The base station device according to Supplemental Note 3, in which the margin of the processing capability of the neighboring base station device is determined by the number of times of executing handover to the neighboring cell within the handover inhibition time, and by the processing capability index.
[Supplemental Note 5]
[0065] The base station device according to one of Supplemental Notes 1 to 4, in which the neighboring base station device is a small base-station device located under the base station device.
[Supplemental Note 6]
[0066] A handover control method for a base station device in a wireless communication system, including:
[0067] storing, in a neighboring base station information storage means, neighboring base station information including handover inhibition information associated with a neighboring cell managed by a neighboring base station device, and a processing capability index of the neighboring base station device; and
[0068] limiting, when the neighboring cell transitions from an inactive state to an active state, handover to the activated neighboring cell of a subordinate mobile terminal device, based on the handover inhibition information and the processing capability index.
[Supplemental Note 7]
[0069] The handover control method according to Supplemental Note 6, in which the handover inhibition information is a handover inhibition timer that is activated when the neighboring cell transitions from an inactive state to an active state, and that indicates a predetermined handover inhibition time, and in which, during the handover inhibition time, handover of the mobile terminal device to the neighboring cell is limited, based on the processing capability index.
[Supplemental Note 8]
[0070] The handover control method according to Supplemental Note 7, in which handover of the mobile terminal device to the neighboring cell is permitted only in a case where the processing capability of the neighboring base station device has a margin, if within the handover inhibition time.
[Supplemental Note 9]
[0071] The handover control method according to Supplemental Note 8, in which the margin of the processing capability of the neighboring base station device is determined by the number of times of executing handover to the neighboring cell during the handover inhibition time, and the processing capability index.
[Supplemental Note 10]
[0072] The handover control method according to one of Supplemental Notes 6 to 9, in which the neighboring base station device is a small base-station device located under the base station device.
[Supplemental Note 11]
[0073] A wireless communication system including a plurality of base station devices, one of the plurality of base station devices, including:
[0074] a neighboring base station information storage means which stores neighboring base station information including handover inhibition information associated with a neighboring cell managed by a neighboring base station device, and a processing capability index of the neighboring base station device; and
[0075] a handover control means which limits, when the neighboring cell transitions from an inactive state to an active state, handover to the activated neighboring cell of a subordinate mobile terminal device, based on the handover inhibition information and the processing capability index.
[Supplemental Note 12]
[0076] The wireless communication system according to Supplemental Note 11, in which the handover inhibition information is a handover inhibition timer that is activated when the neighboring cell transitions from an inactive state to an active state, and that indicates a predetermined handover inhibition time, and in which the handover control means inhibits, during the handover inhibition time, handover of the mobile terminal device to the neighboring cell, based on the processing capability index.
[Supplemental Note 13]
[0077] The wireless communication system according to Supplemental Note 12, in which the handover control means permits handover of the mobile terminal device to the neighboring cell only in a case where the processing capability of the neighboring base station device has a margin, if within the handover inhibition time.
[Supplemental Note 14]
[0078] The wireless communication system according to Supplemental Note 13, in which the margin of the processing capability of the neighboring base station device is determined by the number of times of executing handover to the neighboring cell within the handover inhibition time, and by the processing capability index.
[Supplemental Note 15]
[0079] The wireless communication system according to one of Supplemental Notes 11 to 14, in which the neighboring base station device is a small base-station device located under the base station device.
[Supplemental Note 16]
[0080] A program for implementing, in a computer, a handover control function of a base station device in a wireless communication system, the program implementing, in the computer:
[0081] a neighboring base station information storage function of storing neighboring base station information including handover inhibition information associated with a neighboring cell managed by a neighboring base station device, and a processing capability index of the neighboring base station device; and
[0082] a handover control function of limiting, when the neighboring cell transitions from an inactive state to an active state, handover to the activated neighboring cell of a subordinate mobile terminal device, based on the handover inhibition information and the processing capability index.
INDUSTRIAL APPLICABILITY
[0083] The present invention is applicable to a power saving technique in a wireless communication system and, more particularly, to reduction of a load on a small base-station device.
REFERENCE SIGNS LIST
[0000]
100 , 101 base station devices
100 a , 101 a base station device cells
200 a small base-station cell
300 , 301 mobile terminal devices
110 wireless communication control unit
120 inter-base-station communication control unit
130 handover control unit
140 activation control unit
150 neighboring base station device information table | 4y
|
[0001] This technology relates to treating sludge by shearing, a procedure that is aimed at liquefying and homogenizing the sludge.
[0002] The technology disclosed herein is a development of that disclosed in patent publications U.S. Pat. No. 6,808,636; U.S. Pat. No. 7,736,511; US-2009/107,920; and US-2010/223,969.
[0003] Paunch-sludge, or paunch-manure, is an element of the technology. U.S. Pat. No. 3,767,416 mentions paunch-manure. An article Waste Minimisation and Management in Abattoir Waste - water & Odour Management published by Meat Research Laboratory, Australia, in 1995, mentions paunch manure, and also mentions Dissolved Air Flotation, which is another element of the technology.
[0004] The contents of these publications are incorporated by reference.
BACKGROUND
[0005] For the purposes of the present specification, the following definitions and other points should be noted.
[0006] Sludge is a mixture of water and solid materials. Depending on its water content, sludge may be characterized (when the solids content is e.g 3% or less) as “solids swimming in water”, or (when the solids content is e.g 17% or more) as “stiff cake”.
[0007] A tonne of raw 5%-solids sludge contains 50 kg of solids and 950 kg of water. Handling/transporting/treating such sludge in its raw, watery, state is wastefully expensive, and desirably the sludge is de-watered prior to processing. Sludge is routinely de-watered by mechanically squeezing, centrifuging, etc, to reduce its water content.
[0008] The amount of water that can be removed by routine de-watering depends on the equipment available and other factors; in the case of paunch-manure, or paunch-sludge, it is routinely economical to de-water paunch-sludge to 17% solids. At that, a tonne of raw 5%-solids paunch-sludge, which contains 950 kg of water, after de-watering to 17%-solids, contains only 244 kg of water: the other 706 kg of water has been squeezed out.
[0009] Organic sludge is a mixture of water and organic substances. The term “water”, as used herein, should be understood to include solutions, including saturated solutions, of whatever soluble materials might be present. In the sludges with which the present technology is concerned, the organic substances present in the sludge include a substantial proportion of intact biological cells.
[0010] Intact biological cells contain a good deal of water. When sludge that contains cells is sheared, the intact biological cells are torn apart and ripped open. When this happens, at least some of the water inside the cell is released.
[0011] The distinction is made between free water and captive water, in the sludge. To illustrate this, the example of a blade of grass will be described. The term “solid”, as used herein, means solid in the sense that a blade of grass is a solid article. However, a solid blade of grass contains a good deal of captive-water, and the term “dry-solid” content of the blade of grass is used to indicate the portion of the blade of grass that remains when the grass has been dried, and all the captive-water has been driven off. The mass of a typical biological cell consists of 30% dry-mass bio-solids and 70% captive-water mass.
[0012] The sheared bio-solid material can be dried, e.g by prolonged heating, whereby the captive-water is driven off. The dry solid residue that then remains is the so-called dry-mass of that blade of grass.
[0013] Thus, in a typical batch of biological sludge, e.g a batch of paunch-manure from an abattoir, the dry-mass of the bio-solids might be e.g five percent of the overall mass of the sludge. The remaining 95% of the overall sludge is water (including both free-water and captive-water).
[0014] Thus, a tonne of untreated 5% paunch-manure comprises 50 kg dry-mass of bio-solids, in which is locked 117 kg of captive-water. The 167 kg of grass (comprising 50 kg of dry bio-solids and 117 kg of captive-water) is present in the tonne of 5% paunch-manure sludge, along with 883 kg of free-water.
[0015] Some of the free-water (but (almost) none of the captive-water) can be extracted from the paunch by filtering, mechanical squeezing, centrifuging, or a combination thereof. Typically, the paunch-sludge, after the removal of free-water by centrifuging, will be de-watered to e.g 17% solids; or, in other words, the free-water component has been reduced, in the now de-watered paunch-sludge, from 883 kg to 294 kg. Thus, de-watering transforms the one tonne (1000 kg) of 5%-dry-mass paunch-sludge into 411 kg of 17%-dry-mass paunch-sludge—comprising the 50 kg dry-mass of bio-solids with its 117 kg of captive-water, now mixed with only 294 kg of free-water. The other 589 kg of free-water that was present in the tonne of 5%-paunch-sludge has been squeezed out in order to create the 17%-paunch-sludge.
[0016] The paunch-sludge, now de-watered to 17%-solids, is ready to be subjected to violent shearing. As a result of shearing, some of the captive-water locked up in the grass cells is released, as the biological cells are torn open. Typically, shearing paunch-sludge can be effective to free up (i.e to release) e.g 40% of the captive-water held in the grass cells. Thus, after shearing, 60% of the captive-water is still retained within the remaining bio-solid material of the grass, even though that material is no longer in the form of intact bio-cells. (That remaining water can be driven off by heating/drying.)
[0017] One of the desired results of violent shearing of sludge is to turn the sludge into a homogeneous liquid. As such, the liquefied paunch-sludge is easy to handle and to transport. Liquefied paunch-sludge would be easy to dispose of, e.g by being pumped (injected, sprayed) onto an agricultural field.
[0018] As a result of shearing, the bio-solid (solid organic) material of the cell (with its captive-water content) is torn into small fragments. Typically, after violent energetic shearing, these fragments are small enough, and so well-dispersed in the free-water, that the sheared sludge assumes the characteristics of a thick liquid emulsion, like e.g paint.
[0019] Thus, sheared sludge can be regarded as a homogeneous liquid. When a viscosity test is performed on unsheared wet sludge, often the viscosity reading is a measurement only of the viscosity of the free-water content of the sludge, rather than of the sludge as a whole substance, and thus the viscosity varies when samples are taken form different locations in the sludge. With violently sheared sludge, on the other hand, the sludge is so homogeneous that viscosity measurements of small samples of the liquid sludge are all consistent with each other—as they are with an actual liquid.
[0020] Paunch-sludge, as a substance, is generally regarded as being of negative value; that is to say, disposing of paunch-sludge carries a cost. Liquefying the paunch-sludge offers the possibility that the sheared material can now have value, e.g as a fertilizer, or at least, shearing the material can reduce the net cost of disposal. However, paunch-sludge is very difficult to liquefy, for the reasons discussed below.
[0021] Another material that is produced in abattoirs is the material known as DAF float.
[0022] In abattoirs and in meat handling and packing plants generally, a good proportion of the waste that has to be dealt with arises from fatty tissue. Most of the fatty material is present as small lumps or pieces of solid material dispersed in water. Meat plants use a good deal of water, e.g for cleaning, and the small lumps (including very small lumps) of fatty material are borne away in the wash-down water.
[0023] The fatty material has to be taken out of the water for disposal purposes. One technique is called Dissolved Air Flotation (DAF). Here, water is mixed with compressed air, which dissolves under pressure. When the air-laden water is released into the waste-water, the dissolved air bubbles out of solution, and a myriad of tiny bubbles rises through the waste-water.
[0024] The bubbles attract and pick up the lumps of fatty material dispersed through the wastewater, and carry them to the surface. A scum or froth forms at the surface, in which the pieces and lumps of fatty tissue are contained. This scum or froth is termed DAF-float.
[0025] If anything, DAF-float has even less commercial value than paunch-sludge. To minimize disposal costs, it is usual to de-water the DAF-float. In a treatment station that de-waters paunch-sludge to 17%-solids, the DAF-float would typically be de-watered to e.g 35%-solids.
[0026] 35%-DAF-float has the consistency of cold butter. It is handled and transported as a greasy solid. Generally, it is disposed of in a landfill.
[0027] Returning now to paunch-sludge, although it is desirable that 17%-paunch-sludge be sheared, and thereby made homogeneous, and of the consistency of paint, shearing the 17%-paunch is not in fact effective to achieve that degree of liquefaction, or at least not in a commercially-economical short period of time.
[0028] When de-watered paunch-sludge is placed in a shearing vessel, what happens is that the shearing blades cut a cavity in the solid material, but the rest of the material in the vessel is not drawn into the blades.
[0029] Generally, when shearing sludges, the shearing action can be expected to mix the sludge very thoroughly, and lead to such a degree of homogeneousness that it is impossible to detect differences (i.e any differences, including viscosity differences) between samples, no matter where the samples are taken from over the whole body of sheared sludge. However, that does not happen when the sludge being sheared is 17%-paunch-sludge. The sludge simply resides, in the vessel, where it was deposited, and is not mixed and stirred, or even moved, by the shearing blades.
[0030] Another problem when shearing paunch-sludge is that the solids in the sludge create a high resistance force on the blades. The resistance force is proportional to blade speed, and so the blades tend to slow down, which is bad for efficiency, and is likely to shorten the life of the drive components, and especially of the shearing blades.
[0031] The reasons for these difficulties with 17%-paunch-sludge may be speculated as follows.
[0032] The reason may be connected with the shapes and sizes of the pieces of solid material, in relation to the viscosity of the water in which the pieces are dispersed. The liquid itself, being water, is of very low viscosity. On the other hand, the matted strands of partly-digested grass (which are the major component of paunch-sludge) are held together quite tightly. Thus, as the liquid water is swirled about by the blades, the matted strands of biological material remain held together, the force of the moving water being too weak to detach the individual strands from the matted mass of strands.
[0033] The strand of straw or grass, even having been bitten off, and having been partly digested, is quite long, being 25 mm long or more. Primarily for that reason, it can take a good deal of force to detach one strand from the matted mass. The forces arising due to swirling of a very low viscosity liquid like water are barely enough to detach the individual strand.
[0034] The fact that the strands have the characteristic shape of being long and thin also adds to the force needed to detach the individual strand from the matted mass. A strand that is 25 mm long would be characterized as “long and thin” if its cross-sectional area is less than 5 sq·mm over more than 70% of its length.
[0035] If the strands were shorter, or rounder, they would not be, or might not be, snagged so tightly in the matted mass of strands.
[0036] When at least 50% of the solid material of the sludge is in the form of strands that are long and thin—for example, are more than 25 mm long and less than 5 sq·mm in area—the problem is likely to arise that the matted strands are so highly resistant to being drawn out of the mat that shearing is not effective to draw them out. In sludge with strands like that, only a small degree of matting can be enough to resist the pull of the swirling water. The strands are held in the mat more forcefully than can be overcome by the viscosity of the water.
SOME FEATURES OF THE INVENTION
[0037] It is recognized, as a feature of the technology, that mixing the de-watered 17%-paunch-sludge, in the shearing-vessel, with the de-watered 35%-DAF-float, is effective to enable the paunch-sludge to be sheared, and to be thereby transformed into a homogeneous liquid having the consistency e.g of paint.
[0038] The reasons why this mixture can now very readily be liquefied, in the shearing vessel, may be speculated as follows.
[0039] When shearing first commences, the liquid water passing through the shearing blades is vigorously stirred by the blades. The DAF-float, as it also passes through the blades, despite being quite hard and solid, is quickly broken up, and becomes finely dispersed in the water.
[0040] Consequently, the free-water component of the paunch-sludge, upon being vigorously stirred and mixed together with the DAF-float, is quickly transformed into a thick viscous liquid. Thus, very soon after shearing starts, the long thin strands of solid material are caught up—not now in (low-viscosity) water, but—in a thick viscous liquid. As a result, the forces acting on the long thin strands now are indeed large enough to draw the strands into the shearing blades.
[0041] Once this starts to happens, now the shearing is effective to break up the mat of strands, and to tear the solid material of the strands, and to tear open the biological cells, and to release (some of) the water held captive therein. That is to say, once the viscosity of the liquid medium in which strands are contained increases beyond a threshold, the matted strands of solid material start to be drawn into the shearing blades. Now, liquefaction and homogenisation of the 17%-paunch-sludge can indeed take place.
[0042] The DAF-float, being fatty (greasy), can also be expected to provide a lubricating effect. Thus, the DAF-float being present, the friction associated with high blade forces is reduced. Lubrication makes it easier for the shearing blades to shear the solids, and reduces the abrasive forces on the blades, prolonging the service life of the blades, and reducing the time it takes to homogenize and emulsify the sludge.
[0043] As a result of the liquefaction of the paunch-sludge, the disposal of the paunch-sludge is much simplified, in that the liquefied sludge can be pumped into a storage tank and/or pumped and sprayed onto fields as fertilizer. Paunch-sludge (like any sludge) is generally easier to handle, and to dispose of, when in liquid form. Again, this easy-to-dispose-of paunch-sludge from the abattoir also contains the waste DAF-float material from the abattoir—the disposal of which, by itself, is also troublesome and expensive. The new homogeneous liquefied (emulsified) product, containing both the paunch-sludge and the DAF-float waste-products, might even have commercial value as a stable, odour-free, easily-applied, fertilizer.
[0044] The present technology contains an unexpected synergy. As mentioned, two of the waste-products of abattoirs and meat handling and packing plants generally, are paunch-sludge and DAF-float. As mentioned also, mixing and shearing these two together creates a product that can be readily and cheaply disposed of.
[0045] It is recognized that the proportions in which these two substances are present in the waste products from the meat plants are a good match to the proportions in which they need to be mixed in the shearing vessel. Thus, mixing the two substances together in the ratios in which they are naturally present facilitates the complete disposal of both of them.
[0046] As mentioned, the two substances are de-watered, prior to their being mixed in the shearing vessel. The de-watering should be as thorough as possible, in the commercially-practical sense, bearing in mind the equipment available. Leaving the substance to be treated not fully de-watered is wasteful, in that the sludge with its extra water of course all has to be handled and transported, the containment and treatment vessels have to be larger, and so on. However, it is usually not worth going beyond mechanical de-watering—for example, heating the sludge—in order to reduce its water content. As mentioned, typically, the paunch-sludge will be de-watered to e.g 17%-solids, and the DAF-float to 35%-solids.
[0047] However, in the new technology, the described shearing problem, with paunch-sludge, arises over a wide range of water contents. At the same time, the DAF-float is efficacious to reduce the shearing problems also over a wide range of water content. That is to say, it is the proportions of the dry-solids content of the two substances that is important from the standpoint of alleviating the shearing problems, rather than the overall volumes of the substances.
[0048] It is noted, again, that the liquefied product does, or can, contain (substantially) all of the waste paunch-sludge material, and all the DAF-float material, produced by the abattoir; that is to say, the relative proportions in which those two waste products appear, favours the creation of the synergistic effect as described. Also, such variations in the proportions as are likely to occur in an operational abattoir are unlikely to affect the synergistic effect.
[0049] Of course, there is, or can be, a variation, between abattoirs, in the extent as to which the fatty products are incorporated into the value-products produced by the abattoir. It is mainly the potentially-contaminated and dirty fats that are present in the abattoir wastewater. Thus, it is possible, e.g in an exceptional abattoir, that the quantity of DAF-float is too small to make the required difference to the shearability of the paunch sludge produced by that same abattoir. However, generally, the ratio of the mass-stream of DAF-float to the mass-stream of paunch-sludge is amply sufficient to procure the advantageous effects on shearing, as described.
[0050] Variations in the relative extents to which the two waste products are de-watered prior to mixing and shearing can be expected to have little impact on the synergistic effect. As a generality, the waste products should be de-watered as much as is economically practical. (The more de-watered the product, of course, the smaller the overall mass of product that has to be treated, in the shearing vessel.)
[0051] Too much de-watering is contra-indicated, however. There is a threshold of water/solids ratio beyond which shearing, no matter how energetic and violent, and even with the fatty DAF-float, will not be effective to liquefy the sludge, in that the sludge is just too dry. For this reason, the paunch-sludge should not be de-watered to more than 30%-solids, prior to shearing. The DAF-float should not be de-watered to more than 40%-solids.
[0052] It is not suggested that all the paunch-sludge and all the DAF-float from the abattoir have to go through just the one shearing vessel. Prudent system designers will see to it that the streams of waste products are handled and treated in an economical and efficient manner, and that suitable redundancy is provided to enable servicing, etc.
[0053] It is recognized that the new technology can be applied generally, when a sludge is difficult to liquefy because the sludge contains matted strands of solid material. That is to say, mixing the sludge (solids plus water) with a fatty substance, preferably itself a waste-product, prior to, or when, shearing the sludge, can be effective to enable a non-liquefiable sludge to be liquefied, or to enable an already liquefiable sludge to be economically liquefied to a lower viscosity.
[0054] Furthermore, given that sludges can only be liquefied (economically by shearing) below a certain threshold of solids-content, and given that the inclusion of the fatty substance enables that threshold to be raised, the technology enables a reduction in the overall mass of sludge material to be treated.
[0055] In general, then, the present technology can most advantageously be applied to sludge in which a substantial proportion of the organic solids of the sludge are matted bio-cellular strands. Examples include woody and fibrous substances derived from plants, cellulose filaments, stalks, blades of grass, hay, straw, hair, feathers, and the like. Of course, paunch-sludge is a particular example of an applicable biological sludge.
[0056] In the shearing-vessel, the thickener substance to be added is a substance that, when mixed and sheared with water, forms a viscous liquid, being a liquid having a viscosity that is substantially greater than that of water. The amount of the substance that should be added is an amount that raises enough of an increase in the viscosity of the resulting liquid medium that the tenacity with which the strands are held in the matted mass of strands is no longer sufficient to prevent the individual strands from being snagged by the movements of the liquid medium, and drawn into the shearing blades.
[0057] Preferably, in order for the thickener substance to be efficacious in this regard, the substance should contain lipid; preferably, at least 50% of the dry-mass of the substance should be lipid.
[0058] Given that mixing the water with the thickener takes much less energy than shearing of the solids, which is the main capability of the shearing blades, it can be expected that a homogeneous emulsion of the water and the thickener will form very rapidly. As the viscous emulsion starts to form, the increasing viscosity starts to draw the solid strands into the blades. Now, the biological cells of the solid strands are torn open, thereby releasing (some of) the captive-water. The solid material of the cell is cut up into very small pieces, which are homogeneously dispersed through the liquid medium.
[0059] Preferably, the thickener includes a substantial fatty component. Fatty materials, in water, are present as waste from a number of industrial processes, whereby these materials are often available in large quantities at low or negative cost. Of course, DAF-float is a particular example of an applicable thickener substance.
[0060] The amount of energy needed to liquefy the sludge, with the thickener added, will depend on the particular sludge, the particular thickener, and the particular shearing equipment. Routine experimentation will quickly indicate the energy needed. Skilled designers of sludge shearing systems understand that heating the sludge in the shearing-vessel, changing its pH, and other measures, can increase the efficiency with which shearing creates a homogeneous liquid, and it should be expected that such measures will or might also be efficacious in the present case.
[0061] Heating the sludge, and adjusting its pH, can be effective to enhance the effects of shearing, not only as regards liquefying and homogenizing the sludge, but also as regards reducing numbers of pathogens present in the sludge. System designers may also consider, when shearing sludge, such additional shelf-life stability measures as pasteurization, pH adjustment, addition of antioxidants or preservatives, and the like.
[0062] The liquefied sludge can have utility as e.g an animal feed material or as e.g a substrate feed material for microbial production of bioenergy for example through methane or bio-ethanol production.
[0063] The following benefits of liquefaction of the sludge material can be listed.
(a) Thorough shearing can be advantageous as a means of killing pathogens in the sludge. (b) The homogeneity and emulsification of the liquefied sludge can be effective to increase stability during storage of the sludge, in that new microbe colonies can take e.g months to become established and viable. (c) Liquefaction can make the sludge suitable for use as animal feed, and can make the sludge suitable to be used as a bio-energy substrate source, in that liquefaction renders the material more readily digestible by the animal or bioenergy producing microbes, respectively. (d) Liquefaction makes the sludge easy to pump, and enables the sludge to be sprayed onto or injected into soil.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0068] The technology will now be further described with reference to the accompanying drawing, which is a diagram showing some of the processes that take place in an abattoir, and some of the waste products thereof.
[0069] The arrows 2 represent the passage of slaughtered animals through the abattoir. Paunch-sludge is collected at a paunch-sludge receiving-station 3 .
[0070] In an abattoir, water is used in many of the processes and for cleaning. The resulting waste-water generally contains a good deal of fatty material, and is collected in the fatty-waste receiving station 4 .
[0071] The water containing the fatty waste is passed through a Dissolved Air Flotation (DAF) station 5 . Water under pressure, containing much dissolved air, is fed into the DAF station, its effect being to create bubbles of air in the wastewater. The rising bubbles pick up the fatty waste, whereby a frothy scum 6 forms at the surface, termed the DAF-float.
[0072] The paunch-sludge and the DAF-float are conveyed to de-watering stations 7 . Thus far, the processes are conventional. But now, the de-watered paunch-sludge and the de-watered DAF-float are conveyed to a shearing vessel 8 , having shearing blades 9 that are powered by a motor 10 .
[0073] The shearing blades are switched on, whereby the paunch-sludge and the DAF-float are thoroughly mixed together—with the result, as described, that a (viscous) emulsion forms. The torn-apart pieces of solid bio-cellular material arising from the substances become thoroughly homogeneously dispersed through the emulsion. It can be regarded that the (tiny) solid particles are a component of the emulsion.
[0074] The liquefied sludge is then transferred, using pump 11 , to storage-tank 12 .
[0075] The de-watered sludge, and the DAF-float may be fed into the shearing vessel 8 on a continuous basis or a batch basis. When using the batch basis, a batch of sludge is placed in the vessel, together with a batch of DAF-float. Often, shearing of the batch is done slowly at first, and then faster, since the resistance forces from the sludge diminish as shearing progresses. Shearing is maintained until the sludge is fully liquefied. Then, the shearing stops, and the batch of now-liquefied sludge is transferred out of the vessel.
[0076] In actual tests, shearing was carried out on four samples of paunch-sludge and DAF-float. In each test, the paunch-sludge was de-watered to 17%-dry-solids (being stiff cake, non-pumpable sludge) and the DAF-float was de-watered to 35%-dry-solids (like hard butter).
[0077] In each test T 1 , T 2 , T 3 , T 4 , 0.8 kg of the 17%-paunch-sludge were mixed with a quantity Q kg of the DAF-float. The quantities Q 1 , Q 2 , Q 3 , Q 4 were 0 kg, 0.15 kg, 0.3 kg, and 0.6 kg, respectively. (It should be noted that these masses are dry-masses: thus 0.8 kg of dry mass of 17% sludge represents 4.7 kg overall mass of sludge; 0.6 kg of dry-mass of 35% DAF-float represents 1.7 kg overall mass of DAF-float.
[0078] Expressed as the ratio R of the dry-mass of the DAF-float to the dry-mass of the sludge, the ratios R 1 , R 2 , R 3 , R 4 were 0%, 19%, 38%, and 75%, respectively.
[0079] The outcome of these tests is shown below.
[0000]
T1
T2
T3
T4
dry-mass ratio, R %
R = 0%
=19%
=38%
=75%
initial resistance to shearing
very hi
high
low
negligible
tendency to create cavity
very hi
high
low
negligible
time to liquefy (minutes)
(no liq)
15
8
3
[0080] In T 1 , it was not possible to liquefy the sludge down to a meaningful measure of viscosity.
[0081] In T 2 , it was necessary to resort to pulsing the speed of the shearing blades in order to counter the tendency to form a cavity, and to enable mixing/shearing to get under way.
[0082] In T 3 , pulsing was also resorted to, but to a lesser degree.
[0083] In T 4 , there was no tendency to form a cavity. Liquefaction got under way smoothly and immediately, without any need for pulsing. The liquefied product was highly homogeneous. The viscosity of the final product was 12,000 cP, which is like paint.
[0084] It is noted that the 75% ratio, R %, of DAF-float dry-mass to paunch-sludge dry-mass, in the shearing-vessel, is readily available in the stream of waste products emanating from an abattoir. Preferably, all the paunch-sludge and all DAF-float in the waste streams should be fed into the shearing vessel. If more DAF-float happens to be available, the extra can be added into the shearing vessel substantially without detriment.
[0085] A ratio R of 30% or lower is not preferred; at that, liquefaction takes significantly longer and requires more energy, and the service life of the blades is likely to be shortened. A ratio R of 20% would be the practical minimum, below which the present technology has no more than a negligible effect.
[0086] It is generally true, in the field of shearing sludges, that effects created when shearing small samples can be scaled up to commercial treatment sizes. In this case, the improvement in shearing, when scaled up, can be expected to follow the ratio R.
[0087] It can also be expected that the beneficial effects attributable to the ratio R will be realised with the other sludges and the other fatty substances as described herein. In any event, the prudent systems designers will perform routine experiments to determine the best shearing parameters in the particular application, as they would in any new shearing application.
[0088] Some terms used herein:
M-D-BS is the mass of the body of sludge-solids in the shearing vessel, measured as dry-mass tonnes; M-D-QT is the mass of the quantity of thickener solids in the shearing-vessel, measured as dry-mass tonnes; M-D-Ab-PS is the mass of paunch-sludge solids produced by an abattoir in one day, measured as dry-mass tonnes per day. M-D-Ab-DF is the mass of DAF-float solids produced by the same abattoir on the same day, measured as dry-mass tonnes per day.
[0093] The scope of the patent protection sought is defined by the accompanying claims. The apparatuses and procedures shown in the accompanying drawings and described herein are examples. | 4y
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FIELD OF THE INVENTION
[0001] The present invention relates generally to a continuous coating apparatus and method. More particularly, the invention is directed to a cord coating apparatus and a method for the continuous coating of thin layer of viscous materials on a moving cord or filament.
BACKGROUND OF THE INVENTION
[0002] Coatings of 1-2 μm and less are needed for the treatment of the tire cord and wires to improve tire durability, wire-rubber interfacial bonding, and corrosion aging resistance. It is known to use a continuous method to produce coated wires using apparatus consisting of a coating die which surrounds a wire and an extruder that extrudes coating material into the die around the wire. In industry, such an apparatus has been used in the coating of insulating material around electrical conducting wire where the needed coating thickness was 1 mil and thicker. However, the needed coating of 1-2 μm and less for the tire cord surface treatment is impossible to apply by conventional extrusion die coating process.
[0003] In another known continuous method to control the coating thickness of tire cord down to 1-2 μm or less, an air-wipe is used that wipes off excess coating materials right after a conventional dip-coat procedure. However this method is mainly employed to control the thickness of water base latex coat of a low viscosity coating material. For a high viscosity coating material such as an oil base mixture having a viscosity of 100 SUS and higher, the conventional dip-coat with air-wipe method is very difficult to operate and control. Additionally, the air-wipe which uses a strong air blast to wipe off the excess coating may limit the penetration of the coating material into the inner cord because of the volume expansion of the trapped air inside the cord according to the Bernoulli principle of physical matter.
SUMMARY OF THE INVENTION
[0004] The advantages of the present invention are numerous and are as follows.
[0005] The invention provides an apparatus and method which can be utilized to apply a thin layer of viscous coating material to an elongated continuously moving filament whereby the filament can be cabled, coated, and spooled in a continuous operation.
[0006] The invention provides an apparatus and method for applying a thin layer of latex base coating material to a continuously moving cord for an improved coating penetration.
[0007] The invention provides an apparatus and method for applying a thin layer of coating material with a high coating efficiency.
[0008] The invention provides an apparatus and method that can be utilized to improve cord coating at processing speeds that are limited only by the pay-off and the wire take-up services.
[0009] The invention provides an apparatus and method which optimized the coating mist typically associated with coating operations, thereby reducing the cost of the pollution control equipment and the recycling of excess coating materials.
[0010] The invention provides an apparatus and method that eliminates the need for highly complex machinery.
[0011] The present invention provides an improved wire manufactured by a technique having all the advantages of a conventional wire process but none of the disadvantages.
[0012] The disclosed apparatus has a coating material applicator to deliver a flowable material, an air applicator to supply compressed air, a mixer to mix the flowable material and compressed air, a delivery means to spray the mixed flowable material and air onto a filament, and a coating chamber through which the filament passes. The chamber has a material collector and a coating die, and a sealing attachment with an exit hole is located beneath the coating chamber. The filament is sprayed before it travels into the material collector.
[0013] In one aspect of the invention, the coating material applicator is selected from the group consisting of a constant volume material ejector, an intermeshing positive displacement multi-screw delivery pump, and a gear pump.
[0014] In one aspect of the invention, the delivery means is inclined at an angle relative to the coating chamber and the lowermost end of the delivery means is adjacent to the material collector.
[0015] In another aspect of the invention, the sealing attachment is shaped to form a spherical cone with the hole at the apex, forming an open area through which the filament passes.
[0016] In another aspect of the invention, the coating chamber dimensions can be varied. For example, the top entrance of the coating chamber may have a diameter larger than the main portion of the coating chamber and the exit of the coating chamber may have a diameter less than the coating die.
[0017] In another aspect of the invention, the coating chamber is mounted on a frame capable of linear movement relative to a take-up spool. This helps to ensure smooth and even spooling of the coated filament.
[0018] In another aspect of the invention, the material collector has an interior converging wall to permit collection of any stray flowable material.
[0019] In another aspect of the invention, the coating chamber has a vertical orientation. The vertical orientation of the chamber assist the flow pattern of the flowable material as it is sprayed onto the moving filament and in forming a small volume dip bath through which the filament may pass.
[0020] In another aspect of the invention, a cabling device is operatively associated with the coating apparatus.
[0021] Also disclosed is a method of coating a filament with a flowable material. The method includes the steps of providing a flowable material, providing compressed air, mixing the flowable material and the compressed air, spraying the mixing flowable material and compressed air onto a moving filament to coat the filament, and passing the filament through a material collection die, a coating die, and an exit hole having a diameter not more than the diameter of the filament.
[0022] In another aspect of the method, the filament passes through an open area prior to passing through the exit hole.
[0023] Also disclosed is a method of applying a coating of less than 2 μm on a moving filament. The method includes the steps of moving a filament along a defined travel path, providing a mix of a flowable material and a compressed air, spraying the flowable material and compressed air onto the moving filament, passing the filament through a small volume dip pool, and pulling the filament through a hole having a diameter not more than the diameter of the filament.
[0024] In one disclosed aspect of the method of applying a coating of less than 2 μm on a moving filament, the small volume dip pool has a volume of not more than 1.0 cc of liquid.
[0025] In another aspect of the method of applying a coating of less than 2 μm on a moving filament, there is the further step of passing the filament through an open area after passing the filament through the small volume dip pool and before pulling the filament through the hole.
[0026] In both methods disclosed, the filament may be formed of either steel or an organic material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention will be described by way of example and with reference to the accompanying drawings in which:
[0028] [0028]FIG. 1 is an illustration of the entire coating system with the coating chamber in cross sectional view; and
[0029] [0029]FIG. 2 is another cross sectional view of the coating chamber and other elements.
DETAILED DESCRIPTION OF THE INVENTION
The Apparatus
[0030] Referring to the drawings, and specifically to FIG. 1, the apparatus of the invention will be described. The apparatus has a filament pay-off device 10 , a coating material applicator, a low-pressure air applicator 14 , an air-material mixer 16 , a centering die 18 , a material collector 20 , a coating die 22 , and a filament take-up device 24 .
[0031] The term “filament” is used herein for all strand materials whether a single filament or a cord formed of many filaments. The filaments may be steel, organic, or any other strand material. While the embodiments herein described primarily relate to the manufacture of steel cord for reinforcing various articles, the apparatus of the invention has utility in coating all sorts of filaments other than the filament used in the production of the reinforcement materials.
[0032] The filament pay-off device 10 includes a spool 26 on which the filament to be coated is stored. The spool 26 is mounted on a spindle (not illustrated) to permit free rotation of the spool 26 . Operatively associated with the spool 26 is a brake 28 that restrains the rotation of the spool 26 as the filament 2 is being pulled from the spool 26 so as to prevent entanglements. The filament 2 travels about pulleys 30 as it travels to the coating apparatus.
[0033] At any point 32 along the filament path, depending upon the end use of the coated filament or the initial state of the filament 2 on the pay-off device 10 , conventional wire cabling apparatus, such as twisting, bunching, or stranding machines, may be employed. Thus, many filaments 2 of similar or different sizes may be cabled to the desired wire structure by conventional cabling equipment prior to the coating.
[0034] Alternatively, if the coating apparatus is located in an organic filament manufacturing plant, the pay-off device 10 may be eliminated and the filament may be formed immediately prior to the coating operation. In all instances, conventional forming, twisting, and cabling operations can be used in add to or in substitution of the pay-off device 10 .
[0035] The term “flowable material” is used herein for the general class of coating materials applied by the method and apparatus of the invention. While the specific embodiments herein described refer to viscous oil that carry active ingredients to improve the tire durability, other flowable coating materials are contemplated as being within the general class of materials which can be applied by the method and apparatus of the invention. These materials include those which are initially flowable but later hardened by curing or thermosetting the material and also coating materials which may include up to about 90% by weight of solvent or water to render them flowable and later reversible by driving the solvent or water from the material. In the manufacture of tire steel cords, several different materials can be applied using the method and apparatus of the invention. These include rubber process oil with viscosity up to 2000 SUS, corrosion inhibitor such as calcium salts and the wire-bonding agent such as cobalt salts.
[0036] The flowable material is provided by the material applicator 12 , which may be described as a positive displacement delivery system. The flowable material applicator 12 has a chute 34 by which the material is supplied to the applicator 12 , a material reservoir 36 in which the material is stored, and a positive displacement pump 38 which delivers the flowable material to the air material mixer 16 . An additional control device (not illustrated) may be associated with the positive displacement pump 38 to control the actual amount of flowable material delivered. An exact amount of flowable material is delivered through the tube 40 to the air material mixer 16 .
[0037] If it is desired that the flowable material be mixed with solvent or water, both the coating material and the solvent may be fed into the applicator 12 via the chute 34 . The reservoir 36 may also be provided with a mixing apparatus 42 having associated therewith a separate control. When using temperature sensitive flowable materials, the reservoir 36 may be provided with a temperature control means 44 by which the temperature of the material in the reservoir 34 can be controlled. The fluid material applicator 12 may be a constant volume material ejector, an intermeshing multi-screw pump, or a gear pump, all having some or all of the features described above.
[0038] Since the coating thickness is less than 2 μm, at a regular wire process speed the amount of flowable material needed from a material applicator is about 0.06 cc/second or less. Under this situation, a stable flow rate of viscous material is not obtainable from a conventional fluid material applicator, resulting in poor coating uniformity on the filament 2 . To overcome this difficulty, compressed air is combined with the flowable material. The air applicator 14 supplies compressed air to the mixer 16 through the air tube 46 . The needed air pressure is controlled by device 48 .
[0039] Compressed air provides two major functions. First, the air that is introduced in to the mixer 16 crushes the flowable material into numerous tiny droplets so that the flowable material is uniformly dispersed through the material dispenser tube 52 toward the filament 2 without generating a hazardous mist. Secondly, the higher air pressure at the end of the delivery tube forces the flowable material onto the filament 2 , and toward any interior strands of filament 2 , thereby improving the coating penetration.
[0040] As already noted, flowable material via tube 40 and compressed air via air tube 46 are delivered to the air material mixer 16 . The material is crushed by the compressed air and is delivered to the coating chamber 50 by means of the material dispenser tube 52 .
[0041] Coating of the filament 2 occurs within the coating chamber 50 . The coating chamber 50 has a top entrance bore 54 and a bottom exit hole 56 . The coating chamber 50 houses the centering die 18 , the material collector 20 , and the coating die 22 . A sealing attachment 58 is located beneath the coating chamber 50 and operates with the chamber components to execute the desired coating. The major function and specification of each component will be best understood by reference to the following description.
[0042] Referring to FIGS. 1 and 2, the coating chamber 50 , commences with the entrance bore 54 and terminates with the exit hole 56 at the bottom. Centering die 18 is located below the entrance bore 54 and the coating die 22 is located above the exit hole 56 .
[0043] The size of the entrance bore 54 is determined by the size of the centering die 18 . To permit removal of the centering die 18 for replacement or general maintenance, the entrance bore 54 is slightly larger than the centering die 18 . Additionally, as illustrated in FIG. 1, to hold the centering die in position within the chamber 50 , the size of the centering die is larger than the size of the main portion of the chamber 50 . However, in a different variation, the centering die 18 may be larger than the entrance bore 54 , so that the centering die 18 stays in place at the top of the chamber 50 without any additional external support.
[0044] The size of the main portion of the chamber 50 is determined by the size requirements of the coating die 22 . In the illustrated embodiment, the chamber 50 is slightly larger in size than that of the coating die 22 so that the coating die 22 can be easily slide in or out of the chamber 56 when die replacement or a general maintenance is needed.
[0045] The exit hole 56 has a diameter less than that of the coating die 22 so that the coating die 22 stays at the bottom of the chamber 50 without additional support.
[0046] Located above the coating die 22 is the fiunnel-shaped material collector 20 . The material collector 20 has a converging interior wall 60 that interconnects with the underneath coating die 22 . The interior wall 60 defines a cavity into which stray coating material can be collected. Preferably, the cavity will hold about 1.0 cc of material. The collected material then drips down to the coating die 22 to continue coating the filament 2 . In a different embodiment, both the material collector 20 and the coating die 22 may be replaced with just a single coating die with a flared opening in order to collect any stray coating material.
[0047] Along the wall of the coating chamber 50 there is one or more inclined through-holes 62 , allowing the material dispenser tube 52 to slide into the coating chamber 50 . The tube 52 defines an angle α with filament 2 . Angle α can be any value between 10° and 90°. In a specific embodiment, the angle α is about 45°. As seen in FIG. 1, the end of the material dispenser tube 52 is located close to the material collector 22 and the moving filament 2 so that the flowable material is directed onto the filament 2 and any stray material will collect in the material collector 22 .
[0048] The coating chamber 50 is set inside a support frame 64 . In order to prevent material from leaking from the bottom of the coating chamber 50 , the sealing attachment 58 is inserted between the coating chamber 50 and the support frame 64 . At the center of the sealing attachment 58 , there is an exit hole 66 with a diameter equal or smaller than the overall diameter of the coated filament 4 . The sealing attachment 58 is shaped to form a spherical cone with the hole 66 at the apex, thereby forming an open area 68 . In one embodiment, the area 68 is defined about 120-degree angle bisected by the longitudinal centerline of the attachment 58 . The spherical cone configuration, and the open area 68 , can be preformed before inserting the sealing attachment 58 into position. The configuration can also be formed on a flat piece of sealing attachment 58 by a skillful practice of tightening the screws 70 .
[0049] The sealing attachment 58 provides two functions. First, there is a chance that the coating material may accumulate at the exit hole 66 and then the accumulation will start to drip downwards. Due to the presence of the sealing attachment 58 , the leaking drops are retained in the area 68 around the coated filament 4 , so that a coating of 100% efficiency is obtained. Second, it is possible, but not desired, that some of the tiny flowable material droplets inside the mixer 16 may combine into big droplets on the wire surface, potentially degrading the coating uniformity. To improve the coating uniformity, the sealing attachment 58 smears or smoothes out those big droplets by rubbing the surface of moving coated filament 4 . The sealing attachment 58 is preferably formed of resilience elastomeric material such as rubber with a preferred thickness of about 1-2 mm.
[0050] In FIG. 2, the support frame 64 is shown in side view to indicate the needed alignment of the centering die 18 , and the coating die 22 . Additionally, a housing 72 may be positioned with the support frame 64 to house the coating chamber 50 and maintain the chamber in a vertical orientation.
[0051] Below the base of the support frame 64 is a take-up pulley 74 . As illustrated in FIG. 1, the pulley 74 preferably has a v-groove in which the coated filament 4 travels. Due to the interaction between the surface of the pulley 74 and the coated filament 4 , the coating is further pushed into the filament 4 and any remaining excess spots of coating are smoothed out. To prevent a build up of coating and any possible contamination on the pulley 74 , a shield 76 may be added to the side of the support frame 64 that will wipe off any excess coating. The shield 76 can be formed of any type of cleaning paper.
[0052] A set of guide rollers 78 are mounted on top of the support frame 64 to pre-align the filament 2 prior to the filament 2 entering the centering die 18 .
[0053] The support frame 64 is also connected to a linear drive 80 for the take-up spool 82 . Linear drive 80 travels back and forth along the axis 84 in association with the rotation of the take-up spool 82 during the take-up operation to evenly spool the coated filament 4 onto the take-up spool 82 . The spool 82 may be a conventional spool on which coated filaments are conventionally stored or shipped. The spool 82 is mounted on a spindle (not illustrated) for rotation. Operatively connected to the spool 82 is a spool driver 86 that drives the spool 82 and pulls the filament 2 from the spool 26 of the pay-off device 10 .
The Method
[0054] Filament 2 is unwound from the pay-off spool 26 , passing over any necessary pulleys 30 to prevent the filament 2 from becoming entangled. The illustrated filament 2 may be cabled or otherwise formed prior to passing over the last pulley 30 and passing between the guide rollers 78 . The filament 2 is guided into the coating apparatus by the guide rollers 78 and passes through the centering die 18 .
[0055] A flowable material containing an oil-based, water-based, or organic based coating material to be applied to the filament 2 is stored in the reservoir 36 at a flowable temperature. The flowable material passes through tube 40 and into the air material mixer 16 . Compressed air is also delivered to the mixer 16 via air tube 46 at a desired pressure; the pressure being selected by controls 48 .
[0056] The specific air pressure is closely controlled. The air pressure must be high enough to mix the flowable material in the mixer and force the flowable material down to any central core or strands of the filament 2 , but still low enough to prevent the formation of a mist. To avoid forming a mist, the air pressure must be controlled in accordance to the viscosity of the flowable material. For an oil-based material of 500 SUS viscosity, the air pressure is preferable controlled at 2-3 psi.
[0057] The mixed flowable material and compressed air is delivered by the dispenser tube 52 and is deposited onto the surface of the filament 2 just before the filament enters the material collector 20 and the coating die 22 . Coating material that misses the filament 2 is collected by material collector 20 , and then either drips down to the coating die 22 or accumulates inside the cavity of the collector 20 . Normally the stray material that is collected by the material collector 20 quickly drips down to the coating die 22 with the help of the moving filament 2 .
[0058] The specific amount of the coating material to be applied to the filament 2 is accurately metered. If there is an excess of flowable material, the material may drip from the hole 66 . Also, too great an excess of flowable material of the coated filament 4 may also result in the dripping of the flowable material from the take up spool 82 causing problems in handling the spools 82 . For these reasons, the material applicator 12 is provided with controls.
[0059] However, if the coating layer is thicker than desired, the control is thereafter adjusted to reduce the amount of material being delivered. Conversely, if the coating layer proves to be insufficient, the control is adjusted so as to accumulate a tiny pool of flowable material inside collector 20 for an extra short-term dip coating before the filament 2 passes through the coating die 22 .
[0060] Additionally, if it is believed that at the initial coating act, the actual coating thickness may be slightly less than what is expected and desired, the operator can pre-spray flowable material into material collector 20 for 10-20 seconds before the coating start to generate a short-term dip pool.
[0061] After passing through the coating die 22 , the coated filament 4 passes through the chamber exit hole 56 and into the open area 68 and then through the exit hole 66 in the sealing attachment 58 . The provision of the sealing attachment 58 with the open area 68 provides the filaments 4 with a surprisingly uniform coating thickness along the wire. Conversely, when the open area 68 is not present, coating thickness of lower uniformity is found.
[0062] After passing through the attachment exit hole 66 , the coated filament 4 travels over the take up pulley 74 and is wound onto the take-up spool 82 . To maintain even winding of the coated filament 4 on the take-up spool 82 , as needed, the coating apparatus, by means of the linear drive 80 travels along the axis 84 .
[0063] The operation and function of the take-up device 24 was described earlier. However, the speed at which the take-up device 24 was driven was not mentioned. The speed is not limited in any way by the method of the invention. The pay-off device 10 and the take-up device 24 themselves solely limit the speed of coating when applying any of the coating materials mentioned herein. When the pay-off device 10 is eliminated and conventional cabling operations are substituted therefore, the speed at which the driver 84 drives the take-up device 24 is solely limited by the take-up device 24 itself
[0064] The method of the invention has been successfully used with filaments in a wide range of sizes. The method and apparatus of the invention can also coat cords of rectangular cross-sections and of other cross-sections so long as the coating die 22 can be provided in geometrically similar shapes.
[0065] Coating materials of various types have been successfully applied to filaments of various sizes in accordance with the method of this invention by the apparatus above, the coating materials having a viscosity from about 100-2000 SUS.
THE TIRE STEEL CORD
[0066] For the manufacture of cords used in reinforcing tires, metallic cords are treated to improve the ability of the cored to adhere to rubber and increase the corrosion resistance of the cord. A surprising characteristic of all steel cords coated in accordance with the apparatus and method of the present invention is the coating uniformity and the continuity. The continuity and uniformity of thin coatings applied from solution permits a reliance upon a single coat of the viscous material, something atypical in this industry.
[0067] The flowable material contains a soluble bonding agent and/or corrosion inhibitor. The deposit of the flowable material results in improved wire adhesion, improve cable fatigue resistance and wire corrosion resistance. The treated filaments are then contacted with vulcanizable rubber compositions to form metal reinforced rubber plies. These plies may be used to manufacturer tires and also other rubber articles such as conveyor belts, hoses, and the like.
[0068] The metallic cord to be coated according to the present invention may be steel, zinc-plated steel or brass-plated steel. Preferably, the metallic cord is brass plated steel.
[0069] The steel substrate may be derived from those known to those skilled in the art. For example, the steel used for wire may be conventional tire cord rod including AISI grades 1070, 1080, 1090 and 1095. The steel may additionally contain varying levels of carbon and microalloying elements such as Cr, B, Ni and Co.
[0070] The term “cord” means one or more of a reinforcing element, formed by one or more filaments or wires which may or may not be twisted or otherwise formed. Therefore, cords using the present invention may comprise from one (monofilament) to multiple filaments. The number of total filaments or wires in the cord may range from 1 to 134. Preferably, the number of filaments or wires per cord ranges from 1 to 49.
[0071] The number of cord constructions which can be treated according to the present invention are numerous. Representative examples of such cord constructions include 2×, 3×, 4×, 5×, 6×, 7×, 8×, 11×, 12×, 27×, 1+2, 1+3, 1+4, 1+5, 1+6, 1+7, 1+8, 1+14, 1+15, 1+16, 1+17, 1+18, 1+19, 1+20, 1+26, 2+1, 2+2, 2+5, 2+6, 2+7, 2+8, 2+9, 2+10, 2/2, 2/3, 2/4, 2/5, 2/6, 3+1, 3+2, 3+3, 3+4, 3×4, 3+6, 3×7, 3+9, 3/9, 3+9+15, 4+3, 4×4, 5/8/14, 7×2, 7×3, 7×4, 7×7, 7×12, 7×19, 5+1, 6+1, 7+1, 8+1, 11+1, 12+1, 2+7+1, 1+4+1, 1+5+1, 1+6+1, 1+7+1, 1+8+1, 1+14+1, 1+15+1, 1+16+1, 1+17+1, 1+18+1, 1+19+1, 1+20+1, 2+2+8, 2+6+1, 2+7+1, 2+8+1, 2+9+1, 2+10+1, 2+2+8+1, 3+9+15+1, 27+1, 1+26+1, 7×2+1, 3+9+1, 3/9+1, 7×12+1 and 7×19+1. The filaments in the cord constructions may be preformed, waved or crimped. The preferred cord constructions include 2×, 3×, 1+5, 1+6, 1+18, 2+7, 3+2, 3+3 and 3/9+1.
[0072] The diameter of an individual wire or filament that is encapsulated or used in a cord that is encapsulated may range from about 0.08 to 0.5 mm. Preferably, the diameter ranges from 0.15 to 0.42 mm.
[0073] The tensile strength of the steel filaments in the cord should be at least 3040 MPa-(1200×D) when D is the diameter of the filament. Preferably, the tensile strength of each filament ranges from about 3040-(1200×D) to 4400 MPa-(2000×D).
[0074] The flowable material is applied to the filament 2 in an amount equal to what is needed to form a coat of 1-2 μm or less in thickness.
[0075] While there have been described above the principles of this invention in connection with specific apparatus, it is to be clearly understood that this description is made only by way of example and not as a limitation to the scope of the invention. | 4y
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CROSS REFERENCE TO A RELATED APPLICATION
The present application is a divisional of U.S. application Ser. No. 10/345,513, filed Jan. 16, 2003, now U.S. Pat. No. 6,886,395.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of fabricating a surface probing device and the probing device produced thereby, and more particularly, to a method of fabricating a silicon tip supported by a silicon nitride cantilever for performing surface analysis on a sample.
2. Description of Related Art
Surface analysis methods have advanced to achieve atomic resolution using a probing tip of a surface probing device having an apex of atomic dimensions. The probing tip is usually a tapered silicon structure, often referred to as a stylus, with a base attached to a cantilever arm and a sharp apex that interacts with the surface being probed. More particularly, the parts of the surface probing device include a stylus, a cantilever arm and a mounting section. In addition, the surface probing device may have an electrical connection from the stylus, through the cantilever arm, and to external circuitry for monitoring surface characteristics in a particular mode of operation. Moreover, the probe device may also have a reflective coating on the cantilever arm to accommodate, for example, optical detection techniques. In general, the electrical connection and the reflective coating provide different ways to measure the response of the stylus apex to the surface being analyzed.
An apparatus that uses a surface probing device for surface analysis typically involves a scanning process. During the scanning process, the stylus apex responds to surface characteristics. The response is monitored and generally held constant through a feedback system that causes a slight change in the cantilever arm position. Two notable examples where these general principles apply are scanning tunneling microscopy (STM) and atomic force microscopy (AFM).
In STM, a stylus apex of atomic dimensions on a cantilever arm follows the contour of a sample surface. Electrons tunnel through a near-field vacuum between the conductive apex of the stylus and a conducting sample creating a tunneling current. The tunneling current is very sensitive to changes in the distance between the stylus apex and the conductive sample surface. A feedback system is used to monitor and control the tunneling current at a constant value. Optionally, an optical detection techniques such as interferometry or laser beam deflection can be used to measure the resultant cantilever arm deflection during scanning.
AFM uses a stylus that is mounted on a cantilever arm that has a small spring constant and scans a surface such that repulsive inter-atomic forces between the surface and the stylus apex cause deflections in the cantilever arm position. Again, a feedback system is used to monitor and control the forces between the tip and sample, and an optical detection technique such as interferometry or laser beam deflection are used to measure the resultant cantilever arm deflection during the scanning process. In AFM, different modes of operation may be employed. See, for example, U.S. Pat. No. 6,189,374, filed Mar. 29, 1999, assigned to the present assignee, and entitled Active Probe For An Atomic Force Microscope And Method Of Use Thereof.
Several methods for fabricating surface probing devices with a stylus and a cantilever arm have been reported. Bothra et al., U.S. Pat. No. 5,540,958, describe a method for making a stylus on a cantilever arm by first etching a silicon wafer with a mask to produce protruding shapes of a predetermined size and then depositing a second layer, such as silicon oxide, by electron cyclotron resonance. Shimada et al., in U.S. Pat. No. 5,546,375 describe making a stylus by forming a recessed cavity in a silicon wafer. The cavity is then used to define the structure of the stylus. In U.S. Pat. No. 5,399,232, Albrecht et al. describe a method of fabricating a cantilever arm and stylus again by forming a depressed area in a silicon wafer and using the depressed area to define the stylus shape. In U.S. Pat. No. 5,581,083, Majumdar et al. describe a method for producing a hole at the apex of a stylus. The method uses a voltage applied to a metal coated tip causing evaporation of the metal coating and exposing the underlying silicon apex. Manalis et al., in U.S. Pat. No. 6,156,216, describe a silicon nitride cantilever with a silicon tip but provide no way for making a tip useable for probe microscopy, nor a means to control the characteristics of the silicon tip while removing the silicon nitride covering.
As noted, the combination of a stylus and a cantilever arm is important for many modern surface probing methods. In addition, each method of analysis typically requires a stylus and a cantilever arm with properties tailored to the application at hand. A significant drawback in this regard is that known methods to fabricate silicon styluses supported by cantilever arms include making the cantilever arms from silicon using an etching process. One difficulty that can arise in fabricating surface probing devices with silicon cantilever arms is that the thickness of silicon is difficult to control by etching. Another drawback is that it is beneficial for some applications such as thermal measurement and electrical measurement to make surface probing devices that contain an electrically isolated stylus which can be connected to external circuitry through a conductive metal deposited on the cantilever arm.
Therefore, the field of fabricating such surface probing device is in need of a method for fabricating corresponding styluses and cantilever arms in which the thickness of the cantilever arm is easy to control during the fabrication process and which yields an electrically isolated silicon tip. Moreover, it is important that the stylus be extremely sharp or, alternatively, small. A typical state of the art silicon AFM probe tip has a radius of curvature smaller than 15 nm. However, cantilevers with lower spring constants, such as silicon nitride cantilevers typically have styluses with radii of curvature greater than 25 nm. This is due to the fact that silicon nitride tips are typically molded, thus yielding tips that are necessarily less sharp. Contrary to such silicon nitride tips, silicon tips can be readily sharpened via an oxidation step. Therefore, in applications that require the low force afforded by the silicon nitride cantilever, resolution due to stylus size must be sacrificed.
In sum, a method that workably combines a silicon tip with a silicon nitride cantilever is thus desired to achieve the benefits of both systems, i.e., a low force silicon nitride cantilever and a sharp silicon tip.
SUMMARY OF THE INVENTION
The preferred embodiment overcomes the drawbacks of known methods by providing a method of fabricating a probing device having a cantilever arm that is composed of silicon nitride and which is useful as a low force cantilever sensor. Moreover, the resultant probing device (i.e., probe) has a silicon tip which, in addition to being made of silicon, has a very sharp stylus apex.
According to one aspect of the preferred embodiment, a method of making a probe having a cantilever and a tip includes providing a substrate having a surface and forming a tip extending substantially orthogonally from the surface. The method includes depositing an etch stop layer on the substrate, whereby the etch stop layer protects the tip during process. A silicon nitride layer is then deposited on the etch stop layer. An etch operation is used to release the cantilever and expose the etch stop layer protecting the tip. Preferably, the tip is silicon and the cantilever is silicon nitride and supports the tip, preferably via the etch stop layer.
In another aspect of the preferred embodiment, a method of making a probe includes the steps of providing a wafer and forming a stylus of predetermined width and height on a top surface of the wafer. The method includes sharpening and protecting the stylus with silicon dioxide which, as a result, creates a silicon dixode layer. A silicon nitride is then deposited so as to have a defined thickness, and the stylus is revealed using an etch mask and a subsequent etch, wherein the etch is terminated on the silicon dioxide layer.
According to a further aspect of the preferred embodiment, a method of fabricating a scanning probe device includes forming a cantilever by a deposition process, and integrating a metal tip with the cantilever.
According to yet another aspect of the preferred embodiment, a method of fabricating a scanning probe device comprises forming a cantilever including depositing a layer of a material and then integrating a thermocouple with the cantilever after the depositing step.
In a further aspect of the preferred embodiment, a method of fabricating a scanning probe device includes forming a layer of material and integrating an optical element with the layer, wherein the optical element is accessible from a side opposite a side on which the optical element was integrated with the layer.
In a still further aspect of the preferred embodiment, a method of producing a probe includes forming a cantilever comprising a layer of a first material having a thickness defined by the deposition process, and forming a tip of a second material. In this case, the first and second materials are different, and the tip and the cantilever are coupled. The first material is preferably silicon nitride, while the second material may constitute the substrate material, such as the silicon of a silicon wafer. Alternatively, the second material could be a metal.
Another feature of the preferred embodiment includes a probe having a silicon tip and a silicon nitride cantilever. The tip is supported by the cantilever via an oxide layer.
According to another aspect of the preferred embodiment, a probe for a surface analysis instrument includes a tip and a silicon nitride cantilever. The silicon nitride cantilever is formed using a deposition process.
In another aspect of this embodiment, the tip is silicon and is oxidation sharpened. Moreover, the tip preferably includes a reflective element disposed on the cantilever that includes a front side and a back side. Notably, the reflective element may be disposed on the front side.
In the preferred embodiment, a method for making surface-probing devices can be used to produce devices whereby the silicon material is restricted to the stylus and mounting sections, and the cantilever arms are silicon nitride. An advantage of this method is that the silicon nitride layer is formed by a deposition process rather than by an etching process, thus allowing for better control of the cantilever arm thickness over silicon arms that must be produced using an etching process. Importantly, the preferred method provides flexibility in the fabrication of silicon nitride cantilever arms so that corresponding spring constants can be engineered for specific applications. Additionally, by providing an electrically isolated silicon stylus, the probing device is particularly useful, for example, where small currents are being measured.
In process, a silicon stylus is formed on the top working surface of the wafer by etching the wafer. Once the stylus has been formed, the stylus or the apex of the stylus can be ion implanted to alter the chemical composition. To ensure that the silicon stylus is sharp, the silicon will be oxidation sharpened according to known techniques prior to the deposition of the silicon nitride layer. This oxide layer will also serve as an etch stop when etching the subsequently deposited silicon nitride layer. This etch stop will prevent damage to the silicon stylus during the silicon nitride removal and ensure the requisite sharp stylus. Notably, this oxide layer can also be used as protection during the final cantilever release. This can be quite important because the release process will likely damage the stylus if it is not protected. Using the integrated etch stop is a far better alternative over trying to protect the tip with an additional process step. Using the original passivation will never expose the fragile tip until all processing is complete, and this will result in a higher quality tip and better yield.
A silicon nitride layer is then deposited over the silicon dioxide covered silicon stylus and top working surface of the wafer. At this point, an optional reflective metal coating can be applied and optionally patterned on the front side of the wafer. A protective etch mask is applied on the silicon nitride layer, including over the silicon nitride covered silicon stylus. The properties of the resist and its application are engineered to deposit a thickness of resist less than the height of silicon stylus. The process of controlling deposition thickness is well known to those familiar in the art.
The silicon nitride covered silicon stylus is then etched to expose a desired underlying portion of the silicon dioxide covered silicon stylus apex. The etch will consume some of the protective resist, so if there is slight coverage of the apex this will be removed and it will not interfere with the process. This process can be repeated multiple times in order to fully “clear” the stylus apex without damaging the wafer surface silicon nitride. Notably, in the final iteration of the resist application, the cantilever can also be lithographically defined.
A silicon stylus supported on a silicon nitride cantilever arm is then made by etching the bottom surface of the wafer away in the region where the cantilever is desired. The etch is stopped when the field silicon is completely consumed and only the stylus silicon remains. The protective oxide layer is then removed in an etch that is highly selective to silicon nitride and silicon.
A reflective coating can then optionally be applied to the back side of the cantilever to facilitate optical detection techniques. Note that the reflective coating can optionally be applied, in process, on the front side of the cantilever as highlighted previously.
In another embodiment, a metal stylus supported by a silicon nitride cantilever can be formed by following the above process through the etching of the bottom surface of the cantilever. In this embodiment the bottom surface is fully etched, including the stylus. Since the stylus is completely etched, application of the silicon dioxide layer is optional. If the silicon dioxide layer is used, the silicon dioxide protective layer is then removed, typically using an appropriate etch. Metal is then deposited from the back side of the device. As metal is deposited on, and through, the silicon nitride aperture, the aperture closes. The result of the deposition will be the formation of a metal tip with electrical contact to the base of the cantilever.
By subsequently depositing a different metal onto the front side of the silicon nitride cantilever with metal stylus, a thermally sensitive stylus can be formed. It is well known that dissimilar metals in contact will produce a voltage that is proportional to temperature. In this configuration, the dissimilar metals touch only at the apex. Contact is made to each metal from the front and back sides of the cantilever mounting section, respectively.
These and other objects, features, and advantages of the invention will become apparent to those skilled in the art from the following detailed description and the accompanying drawings. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred exemplary embodiment of the invention is illustrated in the accompanying drawings in which like reference numerals represent like parts throughout, and in which:
FIGS. 1A-D are side elevational views of a probe device being produced according to a preferred embodiment, including showing the steps for making a silicon nitride layer with a protruding silicon stylus and back side reflective coating;
FIGS. 2A-D are side elevational views of a probe device of a preferred embodiment, including showing the steps for making a silicon nitride layer with a protruding silicon stylus and frontside reflective coating;
FIGS. 3A-D are side elevational views of a probe device of a preferred embodiment, including showing the steps for making a silicon nitride layer with a protruding metal stylus;
FIGS. 4A and 4B are side elevational views of a probe device according to a preferred embodiment, including showing the steps for making a silicon nitride layer with a protruding thermally sensitive stylus; and
FIG. 5 is a flow diagram illustrating a method of producing a silicon nitride probe according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment is directed to etching the top working surface of a wafer to form a silicon stylus with a predetermined geometry. Here and throughout the descriptions, working surfaces refer to the surfaces of interest that a specified operation is being performed on. For ease of presentation, “top” refers to the working surfaces of the wafer that are part of the silicon stylus formed or to be formed, while “bottom” refers to working surfaces that are not part of the silicon stylus to be formed or formed. The wafer is typically either a silicon wafer, a p-doped silicon wafer, an n-doped silicon wafer, a p-doped silicon-on-insulator (SOI) wafer or a n-doped silicon-on-insulator wafer.
FIGS. 1A-1D show steps for making a silicon nitride layer with a protruding silicon stylus. A wafer 50 is provided with a top silicon working surface 52 and a bottom silicon working surface 54 . The wafer 50 is a silicon wafer or a silicon-on-insulator wafer. In the case shown, the wafer is a silicon wafer that is p-doped, n-doped or un-doped silicon. The top working surface 52 , as shown in FIG. 1A , has been etched, according to known techniques, the details of which are readily available to produce a silicon stylus 60 with a height from 0.1 μm to 50 μm, but typically about 10 μm. The silicon stylus 60 is a tapered silicon structure that has an apex 62 and a base 64 , as shown in FIG. 1A .
Note that the silicon stylus 60 can be doped at any time during the method described when the silicon stylus or stylus apex is exposed. The preferred method for doping the stylus is by ion implantation, but any known method may be employed. Notably, doping is useful for altering the conductivity of the tip itself. There are many reasons to control the conductivity including reducing electrostatic effects during dynamic operation, and having the ability to use the tip as an electrical ohmic point probe or an electric field probe. When using the tip 60 in such electrical applications, a metal element (not shown) may be connected from the tip 60 to the die or probe mount (not shown) in order to facilitate connection to the instrument. Doping may also be changed in order to use the high doping as an etch stop, for example, in order to make a “shell” tip. It is well known that silicon highly doped with boron is an effective etch stop in silicon anisotropic etches (i.e., KOH, EDP, TMAH). By intensely boron doping the tip, the body of the tip can be etched away from the back side, leaving only the outside shell of the tip. This is advantageous because it will reduce the mass of the tip without affecting its functionality. Operationally, the benefit of a lower mass tip is that it will cause the resonant frequency of the device to increase. Higher resonant frequency cantilevers, with similar spring constants, have been shown to provide higher resolutions and faster responses when used as sensors.
Turning to FIG. 1B , a silicon dioxide (SiO 2 ) layer 66 , is grown over the wafer including the silicon stylus 60 . This layer is grown in conventional fashion in a manner that will cause the silicon tip to become sharper. An example of this would be an oxidation step using steam at 950 degrees C., a well known process. The thickness of the resulting oxide layer should be great enough to serve as an etch stop for the subsequent silicon nitride etch. Typically, 0.25 nm is a preferred thickness for the oxide layer. A silicon nitride layer 68 is then deposited over the silicon dioxide layer 66 . The silicon nitride layer 68 is deposited by one of a group including chemical vapor deposition (CVD), low pressure chemical vapor deposition (LPCVD), plasma enhanced chemical vapor deposition, chemical deposition, evaporation and sputtering, and is preferably 10 nm to 10 μm thick.
As will become apparent, it is the oxide layer 66 that operates not only as an etch stop but as an intermediate “bonding” layer between the silicon tip and the silicon nitride cantilever.
A protective coating 70 is then deposited on the silicon nitride layer 68 . Preferably, coating 70 is a photoresist applied by spin coating, so that the coating thickness is less than the height of the silicon nitride covered silicon stylus 60 . An additional lithography step, which clears any resist from the apex 62 of tip 60 , could be used at this point.
More particularly, the height of the tip 60 is known from prior processing. And, the properties of the resist are typically well known by the manufacturer, with the resist typically being provided with a look-up table that contains values for the final resist thickness for different spin speeds and durations. Notably, even though the apexes of the tips may be covered by the initial application of the resist, the subsequent spin planarazation will clear them adequately. If this is a concern, a quick resist etch may be applied to clear any residual resist “scum” from the apex 62 . This process will leave a very thin coating, to no coating, of resist on the apex of the stylus.
Turning to FIG. 1C , a silicon nitride covered silicon stylus 60 is etched to expose the underlying silicon dioxide layer 66 , but not over-etched to the point that the silicon stylus 60 is exposed. The etch control is accomplished by knowing the etch rates of both the film being etched, the etch stop, and the etch mask of the particular etch tool being used. With these numbers, along with knowledge of the thickness of the film being etched, the etch stop, and the etch mask, a process window can be calculated that will give a range of etch times that will clear the stylus without clearing the etch stop or the etch mask. If these calculations do not yield an adequate etch window, the etch process or etch tool must be changed to increase the selectivity of the etch to the etch stop and the etch mask. This protects the apex 62 of the stylus 60 from this etch, and the subsequent cantilever release etch. In many cases, the combination of the etch selectivity between silicon nitride 68 and the resist 70 , and the height of the silicon nitride coated stylus will require multiple coatings of resist 70 to be applied. This would occur if all the resist is etched off the wafer before the silicon nitride on the silicon stylus is completely removed. The old resist can optionally be stripped off and new resist applied, and the etch continued.
Notably, during the clearing of the apex it is often convenient to pattern the shape of the cantilever. This is done by standard photolithography either during the stylus clearing or in a subsequent lithography step. It should be noted that photoresist need only be used if lithography is employed. Otherwise polyimides, epoxies, waxes, etc. can be used for the tip definition. Also, consumption of resist by the etch can be used, in conjunction with the total resist thickness, to tailor the amount of the stylus 60 that will be exposed. After the stylus has been exposed by the etch, the remaining resist is removed from the top silicon working surface of the wafer in conventional fashion.
Turning to FIG. 1D , a device is now released by etching away the back side silicon. This etch is stopped when the silicon is removed from under the silicon nitride layer 68 (i.e., cantilever), but before the silicon stylus 60 is removed. In the case of an SOI wafer, the middle oxide is used as an etch stop.
The silicon dioxide layer 66 may then be removed. The protective oxide layer is preferably removed in an etch that is highly selective to silicon nitride and silicon, such as 6:1 buffered oxide etch, so that the characteristics of the tip (for example, sharpness) are not compromised.
As a result, the silicon dioxide is removed without unbonding the silicon tip 60 from the silicon nitride cantilever. In sum, an oxide layer 66 is inserted so that the tip 1 ) is protected to the end of the process (i.e., the oxide operates as a passivating layer), and 2 ) is coupled to the silicon nitride, albeit via the oxide. In the completed device, the tip 60 is cleared of oxide on its apex, but again not in the region that affixes the tip 60 to the silicon nitride 68 . Therefore, the method removes the silicon nitride from the tip 60 while at the same time preserves the designed characteristics of the tip. Notably, because the oxide passivation layer protects the tip throughout the entire process, including the exposing of the apex, but also through the release of the cantilever structure, the step of releasing the cantilever 68 via the backside silicon wafer etch does not ruin the tip 60 .
A reflective coating 72 may then be deposited on a back side 74 of the cantilever 68 . Again, this coating 72 may serve multiple purposes including, for example, a surface for reflecting a laser beam toward a photodetector in an optical beam-bounce measurement apparatus. The reflective coating can optionally be applied, in process, on the front side of the cantilever. This is advantageous because the reflective coating can be patterned into a specific shape. An example of a useful shape would be a reflective coating near the free end of the cantilever but not on the base of the cantilever. This configuration also would minimize the residual bending of the cantilever due to stress in the applied reflective film, and bending from thermal effects.
FIGS. 2A-2D illustrate steps for making a silicon nitride layer with a protruding silicon stylus and a front side reflective coating. The process is the same as with respect to FIGS. 1A-1D , only now a reflective film 80 is deposited over the silicon nitride 68 . This film 80 may or may not be patterned separately from patterning the cantilever structure. The film is patterned separately when the desired shape of the reflector is different from the desired shape of the cantilever. This may be done to optimize cantilever parameters such as stress or reflectivity. If patterned separately, it is removed from the stylus stack before the silicon nitride stylus clearing etch. If a separate lithography is not used, this reflective coating can be cleared in the same manner as the silicon nitride 68 , only with a suitable etch. An additional lithography, which clears the resist 70 from the apex 62 of the tip 60 , could be used at this point.
Notably, the process illustrated in FIGS. 2A-2D is contrary to conventional practice in, for example, producing probes for surface analysis tools such as an atomic force microscope. Again, in conventional production, the metal reflector is disposed on the back side of the cantilever in the final step of production because the laser used in the measurement apparatus (e.g., using an optical beam-bounce technique) is typically reflected off the back side of the cantilever. And, in conventional production, the last step is the first time the back side of the cantilever is revealed so it cannot be deposited earlier in the process.
The result of the process illustrated in FIG. 2D is a reflector on the front side of the cantilever, disposed in process prior to the back side being revealed. Because the cantilever is transparent, a suitable reflector results, much how the metalization on a household mirror is disposed on the far side of the glass.
This technique has significant advantages including the fact that the metal reflector can be shaped, and thus can be kept separate from critical elements. Moreover, it is easier to process and more robust, and stress can be better controlled because the substrate is more stable. And, the process yields less worry about residual coating of the tip 60 because the reflective film 80 is actively etched away.
Moreover, this technique is particularly useful when producing thin cantilevers that need reflectors. The AFM industry, for one, seems to be moving towards thinner levers, and therefore thinners reflectors. This process of producing a front side reflector can offer improvements over bulk back side coating because, as noted above, by patterning the reflector just where you need it, you can eliminate stress problems and thermal drift problems.
FIGS. 3A-3D illustrate the fundamental steps for making a silicon nitride layer with a protruding metal stylus 90 . The same process is used as in forming the silicon stylus ( FIGS. 1A-1D ), only the etch is not stopped when the field silicon is clear, but when all the silicon is consumed, as shown in FIG. 3C . If an SOI wafer is used, an extra oxide etch must be inserted, as appreciated by those skilled in the art. A metal film 90 is then deposited from the back side of the cantilever until the hole or aperture 92 formed by the removed silicon stylus is filled with metal and metal protrudes beyond silicon nitride cantilever to define stylus or tip 90 . The result of the deposition will be the formation of a metal tip 90 with electrical contact to the base of the cantilever. Notably, the metal tip will be self-sharpening to a degree. As the aperture closes the apex will come to a point. However, it typically is not nearly as sharp as the silicon tip. This is acceptable as “metal tip” applications usually do not require a tip as sharp as applications that require a silicon tip.
FIGS. 4A and 4B illustrate the fundamental steps for making a silicon nitride layer with a protruding thermally sensitive stylus. The structure of FIGS. 3A to 3D is formed and therefore the previous steps will not be repeated. Thereafter, a dissimilar metal 100 is then deposited on the front or top surface 102 of the cantilever. The junction of the two metals 90 , 100 , which only occurs substantially at the apex 110 of tip 108 , forms a thermocouple. As previously noted, it is well known that dissimilar metals in contact will produce a voltage that is proportional to temperature. Electrical contact is made to the thermocouple from contacting the respective metals 90 , 100 on the mounting section area 104 , 106 , respectively.
Turning to FIG. 5 , a method 110 of producing a silicon nitride cantilever having a silicon tip is shown. Initially, in Block 112 , a substrate, such as a silicon wafer or a silicon-on-insulator wafer, is provided. Then, one or more tips or styluses are formed on the working surface of the substrate in Block 114 . At this point, an optional doping step may be performed to alter the make-up of the silicon stylus(es) in Block 116 , as described previously. Again, this doping step may be performed to alter electrical properties of the tip, or to form a “shell” tip, etc.
Next, in Block 118 , an oxide layer is deposited on the top working surface of the substrate. Preferably, this oxide layer acts as a sharpening step that results in a silicon dioxide layer residing on the silicon substrate including the silicon tips. Then, a cantilever material layer (preferably, silicon nitride) is deposited on the silicon dioxide layer in Block 120 . Once the silicon nitride layer is formed so as to provide a cantilever having a selected thickness, a protective coating is deposited on the top working surface in Block 122 . Preferably, this is a spin coated resist that is deposited in conventional fashion.
In Block 124 , the apex of the tip is cleared of the silicon nitride. This is accomplished by using an appropriate etch. Notably, the shape of the cantilever can be patterned in an optional operation as part of Block 124 .
Importantly, upon completion of clearing the apex in Block 124 , the protective silicon dioxide layer remains on the tip. In Block 126 , the cantilever is released by etching away the silicon from the back side of the wafer. Notably, the integrity of the characteristics of the tip are maintained in this step due to the fact that the silicon dioxide layer remains on the tip.
Once the cantilever is released in Block 126 , the silicon dioxide on the tip (and back side of substrate) is removed using an appropriate etch so as to not compromise the integrity (e.g., sharpness) of the tip in Block 128 . Then, in Block 130 , a reflective coating is deposited on the cantilever of the probe from the back side working surface. Of course, as highlighted above in discussing FIGS. 2A-2D , this reflective coating may be deposited on the front side working surface of the wafer during formation of the cantilever, after deposition of the silicon nitride layer in Block 120 . Method 110 is terminated in Block 132 , to produce a scanning probe device suitable for use in, for example, an atomic force microscope.
Although the best mode contemplated by the inventors of carrying out the present invention is disclosed above, practice of the present invention is not limited thereto. It will be manifest that various additions, modifications and rearrangements of the features of the present invention may be made without deviating from the spirit and scope of the underlying inventive concept. The scope of still other changes to the described embodiments that fall within the present invention but that are not specifically discussed above will become apparent from the appended claims. | 4y
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PREVIOUS FILING INFORMATION
On Oct. 22, 2004 the United States Patent Office received a copy of—and assigned Ser. No. 60/621,569 to—a Provisional Patent Application (PPA) filed by the same inventor hereof. That PPA is incorporated herein by this reference as though set out here in full. Additionally, the PPA is being supplemented by this Regular Patent Application (RPA). Applicant expressly reserves all rights and privileges flowing from the PPA and its earlier official filing date and contents thereof. This RPA follows, and it is supported by the PPA.
Additionally the invention employs to advantage my novel coupling clamps which are depicted and claimed in my pending application entitled FREE SWINGING PORTABLE CUTTING WORK STATION having Ser. No. 10/458,837 filed on Jun. 12, 2003. Particular attention is called to FIG. 7 of that application. That application is incorporated herein as though set forth in full at this point.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention is truck racking systems and more particularly to an improved product and method for enhancing trucks with a racking system of increased versatility and structural novelty. This rack system invention provides a versatility and utility not shown or suggested by any known prior art. Indeed, the racking system of this invention fulfills a long felt need in a novel manner not provided by any known products in the marketplace today.
The invention allows contractors to use racks on pickups and compact, regular and large size trucks for safely carrying a wide assortment of extra long supplies and products. Painters carry long ladders and poles, plumbers carry long pipes and carpenters carry long boards, and the like. On job sites the trucks equipped with my invention can be used for a myriad of tasks such as loading and unloading supplies to/from decks and roofs and for scaffolding purposes along walls being constructed, painted or repaired.
2. Description of Prior Art
The uses of pickup trucks are widespread, and a growing trend for the proud owners of such vehicles is to make them very “dressy”. Thus, commercial demand says that such trucks must look customized as well as be practical for a myriad of uses. In order to increase the hauling versatility, such vehicles have long been equipped with standard racks that are supported above the bed of the truck by known racking posts.
Most pickup trucks have stake pockets located around the sides and corners of the truck body, or “bed”. These pockets surround the periphery of the loading bed of the truck. It is known to insert straight or inwardly angled steel posts into such pockets, which posts carry well known racking systems of the prior art. In conventional prior art designs the rack runners across the bed width and the runners lengthwise along the bed length are bolted or welded directly to the top ends of the four uprights. In either case, however, the prior art structure presents a loss of interchangeability, flexibility and degradation in the strength of the various rack members.
The prior art racks extend above the bed and generally co-exists above the footprint of the bed. There is little in the way of flexibility and no telescoping involved in such prior art. Should such a prior art rack extend beyond the bed outline, as per Track-Racks.com, it does so as a fixed in place cantilever without any telescoping features. Instead, it is simply bolted as a fixed cantilever rack marginally over the cab. At most this over-the-cab extension might go forward only three feet over the cab. In my telescoping invention I can extend up to about seven feet over the cab and hood. The new and novel racking system of this invention also employs risers that fit in the stake pockets just as in the prior art.
In the invention, however, I have developed angled risers which may be turned so as to sweep inwardly or outwardly depending upon the particular configuration of the novel adjusting, pivoting and telescoping of this racking invention. Please note that the outwardly slanting uprights allow a plank to be placed close to a wall or similar immovable structure for added user convenience and safety purposes. With the prior art straight uprights the truck mirrors and other side protrusions prevent the workers from getting very close to buildings with such prior art rack systems.
In summary, the prior art devices are characterized by a limited range of use and suffer severe limitations for long items. Moreover, the prior art racks do not telescope.
We have all seem what that brings into play. The length limitation of standard racks means that extra long items in the prior art are haphazardly tied down with ropes or twine. Such an approach—particularly with do-it-yourselfers—creates extreme safety hazards. Indeed, many times flexible long items are draped over the windshield area and are tied to the front bumper rearview mirrors or other vehicle parts not intended for such uses.
What has not yet been provided, prior to this invention, is a versatile, personalized racking system as first disclosed and claimed herein. The invention is characterized by the key features of a custom “select, erect and customize” your own personalized rack configuration for the needs and style that suits you, the user. Telescoping capability of this racking invention is a first in the truck cargo racking industry. Moreover, the materials used and the rack configurations are both stylish and functional beyond any racks known in the art.
DEFINITION OF SOME RELEVANT TERMS
Set out below are brief descriptions of certain relevant terms which further the understanding of the invention. These terms provide a basis for a detailed teaching of the improvements of this invention in the relevant arts. Such terms are not intended to replace the claims but rather serve as helpful guides in understanding my novel improvements in these arts.
Telescoping Members
Each racking embodiment utilizes the feature of telescoping rack extensions. The tube members for the invention are selected from standard aluminum or stainless steel pipes that are known in the art as 2 inch pipe (2.375 inch O.D.) diameter, for full sized trucks, or 1½ inch pipe (1.900 inch O.D.) for compact trucks. The telescoping inside part is always approximately ½ inch less in diameter leaving about 0.05 inch diameter clearance between the sliding and “fixed” or outside telescope members. Such pipes are available right off the supply chain and thus contribute to a cost saving feature when compared to the prior art welded square steel racks.
Rack System Couplings
My coupling devices are smooth and easy to adjust for one functional mode to another. In cross section my base, collar and rib forming my multifunction coupling is essentially a ribbed circular omega. This unique shape contributes to function and design and to safety purposes as well. One side of the omega collar has been slotted and the other side acts as a limited movement manually adjustable spring for controlled compression of my circular collar surrounding my racking system pipes.
The mounting and adjustment fasteners—including my friction adjustments that control the coupling collar compression—are rounded and knurled for either finger or Allen wrench control. Collar tightening adjustment bolt(s) are transverse to the base and access is readily adjustable for transforming my novel racking systems components as the job at hand dictates.
Split Coupling for Telescoping
My split coupling is used everywhere a telescoping rack section is present and the rack pipes reduce in size from 2 to 1½ inch diameter. This split coupling employs two co-axial omega collars formed on a solid base. Accordingly, two separate fastening modes are manually achieved by selective friction adjustment on either or both parts of the split coupling collar(s) on the solid base. The coupling part holding the smaller sliding rack section includes a collar spacer insert (preferably of PVC or the like) that takes up the 0.05 inch diameter clearance between the telescoping members.
SUMMARY OF THE INVENTION
The racking system of this invention employs riser upright posts that fit in the stake pockets just as in the prior art. Such risers may be turned within their receiving pockets so as to sweep inwardly or outwardly depending upon the particular configuration of the novel racking system. Coupling attachments per se separate the rack runners lengthwise and cross wise from the uprights. Split couplings are present at the telescoping junctions.
Structural tubing of aluminum or stainless steel pipe is preferred for the racking system of the invention. The novel racking system has tubing connections provided with novel adjustable clamps and collars that allow right angle and in-line connections, together with adjustability and telescoping via my new and novel split coupling. No welding is required thus providing additional versatility and interchangeability of parts and structural members.
Connected to such uprights are receiver attachments (couplings) for receiving, supporting and holding in place adjustable connections for rack members. Such “couplings” in turn are themselves fastened to the top end of the upright posts and carry horizontal side to side, and forward to rearward pipe members that define the novel and versatile rack systems provided by the invention.
In the basic configuration of the invention stainless steel posts with either aluminum or stainless steel rails essentially fit the footprint of the pickup bed. The forward and/or rearward tube members may be fitted with end caps as a decorative and sound reducing feature. The strength and power of the invention, however; comes from pipe members carried by couplings that receive telescoping side runners. These telescoping members fit within the coupled side runners and may be extended forward and/or rearward a considerable length for the purpose of carrying extra long loads.
Such racking system as claimed also includes adjustable cross pieces for receiving and holding platform or “plank” sections that may be loaded across the system. Such cross pieces function as a scaffold for worker ease in contractor/homeowner uses on job sites. Such plank sections, of course, are well known but the invention enhances their effectiveness by providing novel ramping connections that facilitate and support ramps within and without the truck bed. Greater versatility for their use is thus achieved by the invention.
In keeping with the variable recreation, residential and commercial construction requirements of today, the racking system invention further comprises platform sections that may be loaded from the ground into the rear of the pickup bed by virtue of a novel tailgate attachment. And ample headroom is provided for loading ATVs, lawnmowers, powered or non powered construction equipment and the like into the bed of a truck outfitted with my invention.
In order to enhance safety and ease in such ground-to-bed loading/unloading, the invention employs a rear cross piece that swings clear from the side runners. Thus, the rearmost cross piece securely latches over one side runner, while its other end is swiveled by my coupling to the opposing side runner. Such connections allow the cross piece to be rotated in place for enhanced stability. Or, it may be pivoted out of the way for headroom and equipment clearance during a loading/unloading process.
The drawing, pictures, and photographs associated with this application are believed sufficient to depict, describe and support claims to the novel features of this invention. Such features include a racking system for connection to the top end of raised upright posts that are inserted into stake openings in a pickup bed and include a novel and new product and method.
The novel features of the disclosed invention provide many novel benefits. Achieved by this invention are some of the following features and benefits as summarized below:
Lightweight and readily transportable. Readily available for easy adjustment and reconfiguration as loads and uses demand. Easy to set up and/or takedown. Easy to reconfigure as on the job requirements dictate. Provides a wide variety of telescoping uses in a simple affordable racking system. Easy adjustment of multifunction coupling attachments. Coupling attachments for reduction from 2 inch to 1½ inch pipe types. Ramping functions with tailgate attachments for ground to bed and bed to plank requirements. Easy hauling of extremely long loads with improved safety and appearance. Flexibility for compact truck usage. Nylon/PVC insert in split couplings. Schedule 10 or 40, extruded aluminum and/or stainless steel finishes. Other features as set forth herein.
DRAWINGS
FIG. 1 is a top perspective view of a truck and enlarged details of the rack invention in use as shown by FIGS. 1A and 1B in accordance with the invention;
FIG. 1C on a separate drawing sheet is an embodiment that more clearly depicts the telescoping feature and a split coupling with a reducing insert feature of my novel telescoping rack system.
FIG. 2 includes FIG. 2A and FIG. 2B wherein FIG. 2A is a collection of clamp variations that show how one collar is used in various configurations to formulate the various embodiments of the racking invention, and FIG. 2B is an partially exploded view showing two of my couplings joined as a corner clamp;
FIGS. 2C and 3 depict perspective views of some of the basic building blocks for the invention in the form of a basic rack that includes the hollow pipes and my capability to receive telescoping rack extensions of various configurations as shown and described hereinafter;
FIG. 4 depicts a perspective view of another embodiment having double rails and telescope receiving capabilities in accordance with the invention;
FIG. 5 depicts a perspective view of another embodiment having rearmost double rails in which a single forward cross member is adjustable and slides back and forth over the cab area in accordance with the invention;
FIG. 6 is an embodiment advance of that of FIG. 5 and depicts a perspective view with the rack, having double rails, an adjustable cross rail and a telescoped extension well forward over the cab area in accordance with the invention;
FIG. 7 depicts a perspective view of yet another embodiment having double rails a telescoped extension forward over the cab area and additional rack support structure both fore and aft in accordance with the invention;
FIG. 8 depicts the embodiment of FIG. 7 with the telescoped members returned and parked in the withdrawn position in accordance with the invention;
FIG. 9 includes FIGS. 9A and 9B which are long and short embodiments, achieving functions similar to that of FIGS. 7 and 8 wherein the double rails take the form of a trombone shaped railing system.
FIG. 10 is another additional embodiment wherein attachment plates are provided for the top side rails of a pocketless truck box and the uprights are formed from curved pipes;
FIG. 11 depicts in highly symbolic form one embodiment for the platforms and ramps as used in accordance with the invention;
FIG. 12 show a rear perspective of the invention having a pair of wide racks as another inventive option allowing one to load equipment from the ground to the bed. This inventive embodiment includes a dropped tail gate and my tail gate bracket mount for a ground/bed/ground ramp.
FIG. 13 includes FIG. 13A and an enlarged 13 B as top perspectives that are useful in explaining a pivoting clearance rail useful in loading from a ground to a bed via the ramp feature of FIG. 12 ; and
FIG. 14 is an alternate embodiment very useful for painters since my couplings allow the racks an upward extension.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1A depicts a regular sized pickup 100 having one of my inventive racking systems 50 in place on the bed 20 . As there depicted, inboard slanting upright posts 14 have been inserted in the pockets of bed 20 . (An outward slanting post 15 is shown in FIG. 5 to be described later). The post slant determines the width for my narrower or wider racking systems.
This FIG. 1 embodiment is a typical example of my novel to racking system selections. It is referred to as a deluxe unit. The rearmost “over the bed part” of the rack 50 may advantageously be fabricated from 2 inch schedule 40 aluminum pipe supported in position by circular pipe openings in a plurality of couplings 10 . Each of my rack systems use a number of such couplings 10 that are configured for different functions in accordance with the rack type under consideration.
As is obvious from a closer study, one will note in FIG. 1 that my coupling 10 is repeated in many locations throughout the rack system 50 . Such couplings are all of the same basic shape and only the functions that they accomplish varies depending upon their position and fabrication for my given rack models. Such couplings 10 are extruded from aluminum stock material, and they make a decidedly and relatively inexpensive—yet highly versatile—building block throughout my various rack models.
In FIG. 1B one can see a vertically oriented pair of couplings 10 , namely 10 A and 10 B, which pair is bolted or otherwise suitably fastened to spaced openings in the top of upright post 14 . These couplings support the upper and lower rails 20 and 25 respectively. Just forward of that coupling pair and holding forward cross rail 30 in a rigid, but adjustable, position is another coupling assembly 10 C. This coupling 10 C is actually a pair of my couplings connected together base to end and forming a corner coupling assembly 150 .
FIG. 2B includes an enlarged view of a partially exploded corner assembly 10 C. In FIG. 2B a base to end junction of my individual coupling units is achieved by knurled threaded assembly fasteners 40 . In this view one coupling 45 A is joined with another to coupling 45 B to form a corner assembly 150 .
Coupling 45 has formed there through a pair of slightly oversized bore holes 40 A (relative to the shaft diameters of fastener bolts 40 ). These oversized fastener openings are parallel to the base is 180 and are located in the shaded quadrant area above the coupling base 180 and slightly below inwardly directed grooves 2 . Ribs 3 are just above a slot 7 , which slot 7 yields or springs back slightly for controlled tension around rail pipe 25 . The function for my couplings 10 depends upon the rack selection and is readily achieved by simply tightening or loosening my transverse-to-the-base tensioning screw 4 .
I use split couplings 155 in several embodiments and always at every telescoping junction. Thus, in FIG. 1B both the upper and lower rails 20 and 25 carry my split coupling 155 at the sliding member telescope junction as rail 25 steps down from 2 inch rail pipe to the smaller sliding telescoped 1½ inch diameter of front telescope slide 60 . In my method of use, the craftsman tightens the anchor part of split coupling 155 on the larger pipe rails 20 (both sides of the rack) and loosens the smaller diameter slide member on both side rails of the system. The user then manually pulls the front telescoping slide 60 forward and tightens the slide tension adjustment screw 4 on the slide part of the split coupling. The reverse step follows a reverse procedure.
FIGS. 3 , 4 , 5 and 6 will be described together in this section of the application since the operational principles have already been covered by the earlier descriptions. Thus, FIG. 3 is essentially the lower rack portion of FIG. 2C and need not be described in detail in view of the foregoing description. The same couplings, rails and cross bars described in connection with FIG. 2C are employed in FIGS. 3 , 4 and 5 with like numbered elements achieving same functions as earlier described. FIG. 6 is the same as FIG. 2C and thus has already been sufficiently described. The double rail rack of FIG. 4 includes an additional upper rail pair 20 further racking capability.
FIG. 5 is referred to as a farm or ranch rack and is particularly useful for bulky relatively lightweight loads such as hay, insulation, foam planks, plastic conduits. I have used my outwardly slanted upright posts in order to increase the hauling capacity for such materials. Again please note that the outwardly slanting uprights allow a plank to be placed close to a wall or similar immovable structure for added user convenience and safety purposes. With the prior art straight uprights the truck mirrors and other side protrusions prevent the workers from getting very close to buildings with the prior art rack systems. Again cross rail 30 , upon selective user adjustment slides back and forth. Every similarly located coupling unit need not be numbered in every Figure since it is believed that persons of ordinary skill in this art will readily understand their functions in view of the earlier descriptions herein.
FIGS. 7 and 8 are taken together and are mostly self explanatory in view of the earlier descriptions of operation for the earlier figures. In FIGS. 7 and 8 it should be noted that the rack invention includes an optional upper railing that parallels the first lower railing. Both of these parallel railing pairs have been equipped with telescoping members. Lower rail 25 has a forward telescope slide 60 whereas upper rail pair 20 has a rear telescoped slide 70 with a dropped rear cross pipe to increase the rack length for carrying long loads across a common horizontal load plane. Lower rail 25 includes a front telescope slide 60 and in this rack model upper and lower pairs of split couplings 155 are employed. Additional front support is provided by upper rail 20 bending down to connect with telescope slide 60 via a corner assembly 45 as earlier described in connection with FIG. 1B .
Very heavy loads may be placed on the telescoped end of the rack system of FIG. 7 without fear of bending or breaking the rack system. An extreme overhang of the forward telescoped slide 60 of the rack proper extends load support out almost to the hood end of a truck so equipped. This forward overhang is a decided point of departure from the prior art and provides added versatility to the invention. FIG. 8 is the same rack as that of FIG. 7 with the telescoped slides parked or withdrawn. It is likewise very strong and rigid. FIG. 8 is not believed to require any further description.
FIG. 9 includes FIGS. 9A and 9B which are telescoped and parked or withdrawn embodiments, achieving functions similar to that of FIGS. 7 and 8 wherein the double rails take the form of a trombone shaped railing system. The trombone double rail also presents a stylish look for that certain market segment. This is considered to be the strongest of the rack systems, but may be less costly to manufacture.
FIG. 10 is another additional embodiment wherein two pairs of attachment plates 180 are provided for the top of both sides of a truck box that may not have any stake pockets. The uprights 15 of FIG. 10 are formed from curved pipes of the type described herein. Otherwise the earlier descriptions are believed self sufficient as explanation of this racking system.
FIG. 11 depicts a symbolic line drawing of a truck and “planks” or “platforms” 190 that are known to the art and are available for use to great advantage with my telescoping rack system invention. These platforms 190 are carried by my couplings that have a lower section of the circular collar segment removed to fabricate semi-circular hooks 195 . (Please see FIG. 13B .) These hooks 195 drop snuggly in place over cross piece 30 of any of my rack systems. Sliding and fastening the positions for my various cross pipes 30 and 40 , as described herein, readily allows such planks 190 widespread usage throughout my various model rack systems. This FIG. 11 also depicts that selected sections of my platforms 190 may be dropped at one end into the truck bed 20 for additional load moving freedom.
Platforms 195 are very handy for contractors since the height of the truck and my rack system elevates workers far above the ground on a secure and moveable base. A fine example is FIG. 14 wherein the rack invention has been extended upwardly for a higher platform for painters. FIG. 14 is believed self explanatory Also note the fact that such platforms 195 may be hooked in the manner herein describe over the elevated cross rails 210 . Obviously the platforms 195 will span rails 210 and form a high scaffold for painters, roofing contractors and the like.
When platforms 195 are removed from my rack system and placed from the rear of the pickup bed 20 to the ground, loading of supplies, various vehicles, tools and equipment is greatly facilitated. FIG. 12 show such an application. Examples of use for sportsmen are the ease and capability to load ATVs, motorcycles, wheelbarrows etc. from the ground into the pickup bed.
When one intends to load an ATV, for example, into the pickup bed along a platform 195 from the bed to the ground, the invention provides another feature wherein the tailgate 198 is equipped by a rail accessory 200 that fits to the top of the tailgate. My semicircular hooks 195 again drop over the pipe 200 attached to the tailgate 198 and provide a long incline ramp from the ground into the bed 20 of pickup 100 .
A still further advantage of my racking system is shown in FIG. 13 wherein the rearmost cross rail 40 is fitted with a snap hook 195 at one end as depicted in the enlarged view of FIG. 13B . A loose swivel or hinge connection is provided by coupling 10 around the rear end of a rail 20 . These connections allows the rear cross piece to drop down over the tail end of one the said rails in one position and be removed from that rail in another pivoting position. Such rotation as shown in FIG. 13 allows the cross rail 40 to swing upward and swivel out of the way as needed to clear the way for headroom into the bed 20 during the example of an ATV loading process.
While my invention has been described with reference to particular examples of some preferred embodiments, it is my intention to cover all modifications and equivalents within the scope of the following claims. It is therefore requested that the following claims, which define my invention, be given a liberal interpretation commensurate with my contribution to the relevant technology. | 4y
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TECHNICAL FIELD
This invention relates to an apparatus for separating oil from water and more particularly, to an oil skimmer assembly which may be readily transported as a unit from one application to another.
BACKGROUND OF THE INVENTION
With oil skimmers utilizing endless belts, typically, the belt is suspended from a driven head pulley. The belt is also passed around a tail pulley that is positioned in a body of water. When the head pulley is rotatably driven, a descending reach of the belt on entering the body of water will pick up surface oil and carry that oil around the tail pulley to an ascending reach of the belt. Wipers are positioned below of the head pulley near the top of the descending reach to scrape oil from the surface of the belt. Collection pans positioned below the wipers receive the separated oil and deliver the separated oil to a collection vessel for recycling or appropriate disposal.
In the past, the tail pulleys have usually either been mounted in a vessel containing the oil and water to be separated or alternately, supported exclusively by the belt. As an example of the latter, if oil is to be removed from a contaminated water well, an elongated belt supporting a tail pulley is dropped into the well, and the weight of the pulley and the belt provide belt tension. Clearly, if the belt breaks, there is a problem because the pulley will be dropped into the well and either lost or, at best, retrievable only through a successful "fishing" operation. Even if the belt does not break, on occasion, a pulley will slip out of the belt as the belt is lowered or during operation, and once again, an operator has, at best, a difficult retrieval process to confront.
Where tail pulleys are rotatably mounted in tanks, as an example, other problems manifest themselves. If the axes of rotation of the head and tail pulleys are not precisely parallel, the belt will not track properly and excessive wear can occur. If the belt is steel, the wear is exacerbated and considerable damage can be caused to both the belt and either or both of the pulleys. Another problem is that it is difficult to obtain and maintain proper belt tension. Here again, the problem is exacerbated if the belt is steel. If a piece of debris gets caught between the belt and the tensioned bottom pulley, the belt will inevitably become damaged due to excessive tension. Further, if the head pulley is equipped with magnets to drive the belt, a malaligned or protruding magnet can cause excessive belt tension that results in belt failure.
Attempts have been made to provide portable oil skimmers which may be transported from place to place as a unit so that the unit may be installed as needed at remote locations. These attempts have all suffered shortcomings, primarily due to the belt tracking and breakage problems.
Another problem is that when endless belt oil skimmers are used in quiescent bodies of water, their efficiencies can be relatively poor. The relatively poor efficiency is due to the fact that the belt picks up oil as it enters a water body and if the body is quiescent, the surface in the vicinity of belt entry soon becomes relatively oil free. Further, pick-up must wait for a relatively slow migration of oil from portions of the body surface remote from the belt entry location.
SUMMARY OF THE INVENTION
An oil skimmer made in accordance with the present invention is readily suited to be transported as a unit and yet does not suffer the belt breakage and tracking problems of prior attempts. A skimmer made in accordance with this invention has a frame which includes a motor support section which is near the top when the skimmer is in use. A gear motor is pivotally mounted on the support section. The pivotal mounting, together with an adjustment interposed between the motor and the support section, permit ready adjustment of the alignment of the rotation axis of a motor output shaft until a driven belt appropriately tracks on a head pulley and does not engage and excessively wear the belt and side flanges of the head pulley.
A stabilizer bar depends from the support section when the skimmer is in use. A headed shaft carries a tail pulley and connects it to the stabilizer bar. The tail pulley is free to float radially and axially relative to the headed shaft through a predetermined range of motion. The headed shaft permits the tail pulley to float so that tension on an endless belt which is around the two pulleys, is provided by the weight of the tail pulley and the belt itself. While the weight of the belt and tail pulley provide the tension, the headed shaft nonetheless provides a constraint on the range of tail pulley motion relative to the stabilizer bar so that, as an example, should the belt break, the tail pulley is still connected to the remainder of the skimmer. Securement of the tail pulley to the stabilizer bar also enables transport of the skimmer as a unit.
Because the tail pulley is floatingly mounted and the orientation of the motor output shaft and with it the head pulley, is adjustable, the tracking problems and the attendant excessive belt and pulley wear experienced with the prior art are avoided. Since the tail pulley is floating within a limited range, prior problems in obtaining and maintaining appropriate tension with a mounted pulley are avoided while the "fishing expeditions," which all too frequently occurred with prior art floating pulleys, are avoided.
Another feature of the invention resides in the provision of a tail pulley provided with a circumferentially spaced set of L-shaped spokes. The arms of the spokes are positioned radially while the legs project orthogonally from the outer ends of the arms in the direction of pulley rotation. The spokes also function to agitate the body and push oil on the surface toward the belt entry, oil pick-up location.
Accordingly, an object of the invention is to provide a novel and improved oil skimmer which is transportable as a unit, and a method of operating an oil skimmer to minimize pulley and belt wear and problems attended to belt breakage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the improved oil skimmer of the present invention mounted on, for purposes of illustration, a 55-gallon drum shown in phantom;
FIG. 2 is a sectional view of the skimmer of FIG. 1;
FIG. 2A is an enlarged view of the pulley portion indicated by the circle 2A of FIG. 2;
FIG. 3 is a fore shortened sectional view on an enlarged scale with respect to FIGS. 1 and 2 showing the head pulley, the motor alignment adjustment, the tail pulley and the tail pulley support shaft; and
FIGS. 3A and 3B are enlarged views of the head and tail pulley portions indicated by the circles 3A and 3B of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings of FIGS. 1 and 2 in particular, an oil skimmer embodying the present invention is shown generally at 10. In FIG. 1, the oil skimmer is shown mounted on a 55-gallon drum illustrated in phantom at 12. As shown, the skimmer 10 is positioned to remove surface oil from a body of water contained in the drum.
A support arm 14 is fixed to a mounting bracket 15. The support arm 14 is clamped against the inner surface of the drum 12 by bolts 16 which are threaded into the mounting bracket 15.
The support arm 14 forms a part of a frame. The frame also includes an upper motor support section 18. A gear motor 20 is connected to a vertical portion 21 of the support section 18 by three bolts 22. Springs 25 are respectively around the bolts 22 and interposed between the bolt heads and the vertical portion 21. Adjustment of the bolts against the action of the springs adjusts the attitude of an output shaft 30 of the gear motor 20. Thus, horizontal angular adjustments are accomplished by adjusting an upper pair 22a, 22b of the bolts 22. Vertical adjustment is accomplished by adjusting a lower bolt 22c, the upper bolts, or all three of the bolts.
A head pulley 32 is mounted on the output shaft 30. The head pulley includes inner and outer side flanges 33, 34 which are, in the embodiment shown, connected together in spaced relationship by a set of spaced L-shaped spokes 35. As is best seen in FIG. 3A, each of the head pulley spokes is L-shaped in cross section with arms 37 being disposed radially and legs 38 projecting orthogonally from the arms 37 at the inner ends of the arms.
A set of magnets 40 is provided. Each magnet is mounted in axially spaced relationship on one of the spoke arms 37 with the arm legs 38 serving to support the magnets. The magnets 40 have outer surfaces disposed in an imaginary cylinder which is coaxial with the shaft 30 in order that the magnets drivingly engage an endless steel belt 42.
A stabilizer bar 44 depends from the support section 18, forming a further part of the frame. The stabilizer bar projects downwardly and, when positioned for use as illustrated in FIG. 1, into the body of liquid contained in the drum 55.
A tail pulley 46 is provided and is positioned at least partially in the body of liquid when the device is in use. The tail pulley 46 includes a hub 47, having a through bore 48. A bolt 50, having a body 51 of a diameter less than the diameter of the bore 48, extends through the bore and is threaded into the stabilizer bar 44. A washer 54 of a diameter greater than the bore 48 is around the body 51 and between bolt head 52 and the tail pulley 46.
As is best seen in FIG. 2, the bolt body 51 is axially longer than the axial dimension of the tail pulley 46. The bolt 50, together with the washer 54, function as a tail pulley shaft permitting the tail pulley to float relative to the shaft by an amount limited radially to the difference between diameter to the bore 48 and of the body 51. Floating motion of the tail pulley axially is limited by constraint of the stabilizer bar 44 and the washer 54 and thus to a distance which is the difference between the axial length of the body 51 and the hub 47.
The tail pulley 46 is supported by the belt 42 and, as has been indicated, free to float within a limited range relative to the bolt 50. The tail pulley, like the head pulley, has spaced inner and outer annular flanges 56, 57. The flanges are secured to the hub 47 near its ends. The tail pulley also has its inner and outer flanges interconnected by a circumferentially spaced set of L-shaped spokes 59. Arms 60 of the spokes 59, like the arms 37 of the head pulley spokes 32, are radially disposed. In contrast to the head pulley, legs 61 of the tail pulley spokes project orthogonally from the arms 60 at the radially outward ends of the arms. The legs 61 project from the arms 60 in the direction of pulley rotation as indicated by arrow 63, FIG. 3. The arms have outer surfaces disposed in an imaginary cylinder that is coaxial with the hub 47 and are sequentially in driven engagement with the belt 42.
Operation
In use, the oil skimmer 10 is carried as a unit to the body of water from which oil on the surface is to be removed. If the body is in a 55-gallon drum, as illustrated in phantom in FIG. 1, the unit is then mounted on the barrel and the bolts 16 are tightened to clamp the support arm 14 against the barrel and fix the skimmer 10 in place.
The motor 20 is then energized to cause the head pulley 32 to rotate in a clockwise direction. Through the engagement of the magnet pairs 40, the steel belt 42 is driven such that a descending reach 65 descends into the body of liquid in the drum. As the descending reach 65 enters the drum, assuming there is oil on the surface of the water, the oil will adhere to both inner and outer faces of the belt. The belt then passes around the tail pulley 46. Due to the use of the spokes 59 rather than a cylindrical surface, transfer of oil from the inner surface of the belt 42 to the tail pulley is minimized.
An ascending reach 66 of the belt 42 carries the oil upwardly to and over the head pulley 32. At a location near the top of the descending reach 65, inner and outer wipers 68, 69, of conventional construction, engage the descending reach 65 and wipe the oil from it. The wiped oil is caught by a collection vessel 70 and thence discharged through a discharge hose 72 for suitable recycling or disposal.
As the operation continues, appropriate tension is maintained on the belt through the weight of the belt itself and the tail pulley. The weight of the two alone provides the tension because the tail pulley is free to float within the described limited range of radial and axial movement.
Should there be a problem with the belt tracking appropriately on the head pulley, adjustment is accomplished by loosening or tightening the adjustment bolts 22 until the belt is tracking properly between, and without engaging, the inner and outer flanges 33, 34.
The tail pulley spokes provide one of the outstanding features of the invention. That is, that the L-shaped spokes tend to agitate the fluid. Ideally, the tail pulley is only partially submerged so that the spokes will break the surface as they approach their maximum height. Since the spokes are L-shaped with their legs projecting orthogonally in the direction of rotation, the spokes tend to trap surface oil and push the surface oil toward the descending reach 65 to enhance the oil pick-up efficiency of the belt.
Although a mechanism embodying the present invention has been illustrated and described in considerable detail, the present invention is not to be considered limited to the precise construction disclosed. Various adaptations, modifications and uses of the invention may occur to those skilled in the art to which the invention relates and the intention is to cover all such adaptations, modifications and uses which fall within the spirit or scope of the appended claims. | 4y
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BACKGROUND OF THE INVENTION
The existence of tumor neoantigens in experimental animal tumors has been known for many years. There has been increasing evidence that human cancers, too, express tumor neoantigens that are recognized by humoral and cellular reactions of the host to the cancer cell or its products, in in vitro assays. See generally Shuster et al., Prog. Exp. Tumor Res., 25 89 (1980). This organ-specific neoantigen is shared by all cancers arising from the organ, so that patients with similar cancers will respond to each others cancer neoantigen.
It seems that human cancers may stimulate the hosts' immunologic response. Some prostatic carcinoma patients, for example, respond with a delayed cutaneous hypersensitivity reaction to injected tumor extract of the same histogenesis. Cell mediated cytotoxicity to the cancer was shown to exist in patients with prostatic carcinoma, especially those with stage B lesions.
With the discovery of the phenomenon of leucocyte adherence inhibition (LAI) a comparatively simple in vitro technique for measuring the hosts' antitumor immune response became available. See for example U.S. Pat. No. 3,999,944, issued Dec. 28, 1976 which describes the tube LAI assay for detection of the presence or absence of breast cancer in subjects. The extensions of the tube LAI to other tumor disease states is described in U.S. patent Ser. No. 68,378, filed Aug. 21, 1979, inventors Marti et al. Specific tumors disclosed include malignant melanoma, bladder carcinoma, ovarian cancer and cervical cancer.
The LAI assay is based on the observation that leucocytes from patients with cancer after being incubated in vitro with extracts of cancer tissue of the same organ and histogenesis, lose their former ability to adhere to glass, by binding to the tumor antigen.
One of the limitations of the LAI assay was the fact that substantial percentages of advanced cancer patients with various types of cancers do not have a measurable antitumor response and thus produce a false negative in the test. This fact limits the practical utility of the LAI in providing a broad scale clinical assay for cancer.
Failure of substantial numbers of cancer patients to express an antitumor immune response is particularly exemplified by the situation with prostatic carcinoma althought it can also be documented with breast, lung, stomach, pancreas, colon, bladder and melanoma cancers.
It has been found, for example, that relatively few patients (14%) with prostatic carcinoma had a measurable antitumor response. However, their tube LAI-positive responses were stastically greater than control subjects (1.5%) with or without benign prostatic hyperplasia (BPH).
The tube LAI procedure has also been previously described in detail by Grosser and Thomson, Cancer Res., 35 2571 (1975). In brief outline the procedure utilizes samples each containing B 0.1 ml of a peripheral blood leucocyte suspension (1×10 7 cells/ml) which are incubated with either specific or nonspecific tumor antigen extracts (˜100 μg in 0.1 ml). The tubes are incubated horizontally for 2 hours at 37° C. in a 5% CO 2 humidified atmosphere. After 2 hours, the tubes are carefully placed vertically, and a sample of the non-adherent cells are counted by image analysis driven by computerized-linked instruments. The difference in non-adherent cells in the presence of cancer and a control tumor extract is expressed as a nonadherence index (NAI): ##EQU1##
Based on clinical experience with the assay it was determined that NAI's of 30 or greater are considered positive since greater than 95% of the patients without the specific cancer had NAI's of 30 or less.
The necessity in the above methodology that the nonadherent cells be counted by an automated computer linked counter is a further obstacle to the methodology becoming a widely accepted procedure since the cost of such instrumentation is prohibitive for most laboratories and requires the services of a highly trained technician; another expensive, acceptance limiting burden on the methodology.
DESCRIPTION OF THE INVENTION
The present invention relates to improvements in carrying out the LAI assay which result in a simpler, more efficient procedure which does not require sophisticated instrumentation or the services of highly trained technicians to carry out. In addition, the improved LAI of the present invention provides and can be used to estimate the tumor burden.
In one aspect of the present invention, greatly enhanced responsiveness of peripheral blood leucocytes (PBL) samples can be achieved by incubating such samples with an agent which maximizes the intracellular cAMP levels in such leucocytes. Suitable agents for this purpose include compounds which are known to elevate cAMP levels in leucocytes either by stimulating its synthesis or preventing its destruction or combinations thereof.
Compounds which are useful to stimulate synthesis of cAMP in cells include the prostaglandins, either natural or synthetic analogs and prostacyclins. Preferred cAMP synthesis stimulating compounds include prostaglandin E 2 (PGE 2 ) and synthetic analogs such as the compounds of the formula ##STR1## wherein R is hydrogen or lower alkyl; R 1 is hydrogen, lower alkyl, lower alkoxycarbonyl, --CH 2 OR 8 , carboxy or ##STR2## R 6 is hydroxy or hydroxy protected with a hydrolyzable ether or ester group; R 8 is hydrogen or lower alkyl, R 9 is hydrogen, lower alkyl or fluoro; R 9 ' is hydrogen or lower alkyl; and the dotted bond can be optimally hydrogenated and enantiomers or racemates thereof as disclosed in U.S. patent application Ser. No. 25,972 filed Apr. 2, 1979, entitled "11-Substituted Prostaglandins", inventors George William Holland et al.
Preferred compounds are obtained when R is hydrogen, R 1 is lower alkyl and R 6 is hydroxy.
A particularly preferred compound from this group for use in the practice of the present invention is nat. 11 R-methyl-16 R-fluoro-15.R-hydroxy-9S-hydroxyprosta-cis-6-trans-13-dienoic acid which, in alternative nomenclature, employed in the aforesaid application is referred to as 7 [3 alpha-methyl-5 alpha-hydroxy-2 beta (3 alpha-hydroxy-4 fluoro-1-trans-octenyl)-1-alpha-cyclopentyl]-cis-5-heptenoic acid.
The terms "lower alkyl" "lower alkoxycarbonyl" and "hydrolyzable ether or ester group" are intended to have the meaning and scope provided to such terms in the aforesaid U.S. patent application Ser. No. 25,972. Other cAMP synthesis stimulators such as aminophylline may be used in conjunction with the aforesaid prostaglandins, preferably in about equimolar concentration.
Additional prostaglandin compounds useful to stimulate synthesis of cAMP in cells include compounds of the formula ##STR3## wherein A and B are individually hydrogen or form a carbon to carbon bond, R 4 is hydrogen or lower alkyl; R 1 is hydrogen or lower alkyl; R' is fluoro, lower alkyl or trifluoromethyl; R is hydrogen, fluoro or lower alkyl; and the dotted bond can be optionally hydrogenated which are disclosed in U.S. Pat. No. 4,212,993, issued July 15, 1980.
Preferred compounds are obtained when A and B form a double bond, R 4 is hydrogen, R 1 is lower alkyl, R' is fluoro and R is hydrogen and the dotted line is a double bond.
A particularly preferred compound from this group for use in the practice of the present invention is nat. 11R-methyl-16R-fluoro-9,15-dioxoprosta-cis-5-trans-13-dienoic acid.
Compounds which are useful in the prevention of cAMP destruction in lymphocytes include the phosphodiesterase inhibitors. Preferred phosphodiesterase inhibitors include a class of substituted benzylimidazolidenones which are disclosed in U.S. Pat. No. 3,636,039, issued Jan. 18, 1972. A particularly preferred compound of this group is d,l-4-(3-isopropoxy-4-methoxy-benzyl)-2-imidazolidinone.
The incubation is conveniently carried out for a short period such as from 2 to 5 minutes at room temperature.
It has further been found that the concentration of the agent which is used in the preincubation to maximize cAMP levels in the lymphocyte samples is critical. Thus, for example, when prostaglandin E 2 is utilized in the preincubation with lymphocytes from prostatic cancer patients it was found that molar concentrations of 10 -4 and more, or 10 -7 and less, did not stimulate a positive response while a positive reponse was achieved by preincubation with molar concentrations of 10 -5 and 10 -6 (10 -5 providing the maximum response). The critical molar concentration for any agent utilized in the practice of the present invention with any lymphocyte sample from different types of cancer can be ascertained by simple titration experiments using varying molar concentrations of the agent with samples from a single lymphocyte source and determining the non-adherence index. Suitable sources of lymphocytes from other cancers include breast, lung, stomach, pancreas, colon, bladder and melanoma cancers.
In a further aspect of the present invention the determination of the non-adherence index is simplified by utilizing a vital cell dye which selectively binds to living leucocytes to stain either the adhering or non-adhering cells. Instead of counting the individual adhering or non-adhering cells by image analysis driven by computerized-linked instruments as previously utilized, it is possible, by extracting the dye from the separated adhering or non-adhering cells and measuring the optical absorption of the extracted solution, in a spectrophotomer to correlate the resulting reading with values obtained from known quantities of cells to thereby determine the number of non-adhering cells which number is used in the computation of the NAI as described above. Such procedure simplifies the equipment needed for carrying out the LAI and allows one to employ a laboratory technician for this task rather than a trained specialist.
Suitable dyes for use in this aspect of the present invention include those that will stain viable leucocytes and which are extractable in either acid or base without affecting the dye color. Examples of useful dyes in the practice of the present invention include methylene blue, nonspecific esterase and neutral red. A preferred vital cell dye is methylene blue which can be extracted from the test cells by using a dilute aqueous mineral acid such as dilute hydrochloric acid.
While it is desirable to utilize both aspects of the present invention in combination to achieve the maximum benefits to be derived from these improvements in methodology, it is also possible to employ either of these aspects independently of each other.
The improved LAI of the present invention can be conveniently carried out utilizing reagents contained in kit form. Such a kit comprises the following:
a vial containing a cancer antigen to be assayed sufficient for a multiplicity of tests;
a vial containing an unrelated cancer antigen sufficient for a multiplicity of tests;
a vial containing a sufficient amount of an agent which maximizes the cAMP levels in test leucocytes for a multiplicity of tests; and/or
a vial containing a sufficient amount of a vital cell dye.
The present invention is further illustrated by the following Examples.
EXAMPLE 1
Materials and Methods
Patients and controls:
In a clinical study 37 patients with prostatic carcinoma, ranging in age from 65 to 72 years, were tested: 3 with Stage A, 6 with Stage B, 5 with Stage C, and 23 with Stage D. The staging was in accordance with Whitmore's classification, Cancer 32, 1104 (1973). Fifty-seven patients with histologically diagnosed BPH were studied and included among the control group; they were tested before surgery to correlate the LAI results with latent carcinoma (Stage A) found from transurethral resection and retropubic prostatectomy specimens. Other control subjects included the following: 22 patients with benign genitourinary (GU) disease other than BPH, 8 patients with genitourinary malignancy other than prostatic carcinoma, 29 patients with benign diseases other than the genitourinary system, and 12 patients with malignant diseases other than the genitourinary system. None of the patients had received chemotherapy or radiation therapy at the time of the study.
Tissue extracts:
Prostatic carcinoma extract was prepared from malignant prostate tissue that was removed from metastatic lesions of the liver and retroperitoneal lymph nodes of fresh autopsy material. Similarly, the nonspecific cancer extracts were lung carcinoma and malignant melanoma, metastatic to the liver. The tumor extracts were prepared, titrated, and diluted optimumly for the LAI assay as described previously by Grosser and Thomson, Cancer Res., 35, 2571 (1975).
Tube LAI assay:
The test was performed as previously described in detail, by Grosser and Thomson, supra. Briefly, 0.1 ml of a peripheral blood leucocyte suspension (1×10 7 /ml) was incubated with both specific (prostatic carcinoma) and nonspecific (lung carcinoma or malignant melanoma) tumor antigen extracts (≃100 μg in 0.1 ml). The tubes were incubated horizontally for 2 hours at 37° C. in a 5% CO 2 humidified atmosphere. After 2 hours, the tubes were carefully placed vertically, and a sample of the non-adherent cells were counted by image analysis driven by computerized-linked instruments. The difference in non-adherent cells in the presence of prostatic carcinoma and a control tumor extract was expressed as a non-adherence index: ##EQU2## NAIs of ≧30 were considered as positive because previous results showed that >95% of patients without the specific cancer had NAIs >30.
Tube LAI assay with Prostaglandin E 2 (PGE 2 ):
The laucocytes were tested in the tube LAI assay with and without preincubating the cells with PGE 2 . One portion of the cell suspension was plated in LAI assay as described by Grosser and Thomson. The other portion of the cell suspension was incubated in 0.5 ml of Medium 199 containing PGE 2 (10 -6 M) for 5 minutes. The concentration of PGE 2 used was critical, for 10 -4 and more, or 10 -7 and less, did not stimulate a positive response. Then the cells were diluted with Medium 199 to reach the appropriate cell concentration of 1×10 7 /ml. The cells were plated in the tubes, and the assay was conducted as previously described by Grosser and Thomson.
Results
Tube LAI assay in prostatic carcinoma and control patients:
The NAIs of each patient tested were determined. Leucocytes from 2 out of 23 (8%) patients with Stage D and 1 out of 5 (20%) patients with Stage C were reactive. Of Stage B patients only 1 of 6 (16%) reacted. All 3 patients with Stage A had their cancer found incidentally in surgical specimens for BPH (5%, 3/60); one of the 3 was LAI positive. There were 9 patients with localized disease (Stage A and B) of whom only 2 (22%) reacted compared to 28 patients with advanced stage of disease (Stage C and D) of whom 3 (11%) reacted.
Although the number of LAI-positive patients with prostatic carcinoma was small (14%, 5/37), the difference from the control group was statistically significant (Chi square, P<0.05). Table 1 shows that the mean NAI of prostatic carcinoma patients was 11 and differed from the mean NAI of 2 for the control subjects. (Student's independent t test, P<0.02). Naught of the 57 patients with BPH were reactive to the malignant prostate extract. Of the 71 other controls tested, 2 were positive (2.6%); one was a woman and the other was not retested. Because of the small number of patients tested in each stage of the disease, no statistical significant difference was observed between the different stages of prostatic cancer.
TABLE 1______________________________________Summary of patients tested by tube LAI for reactivity toProstatic Carcinoma extract. .sup.+ NAI'sPatients studied No. No. (%) Mean NAI.sup.+______________________________________Prostatic carcinoma: 37** 5(14)** 11Stage A 3 1(33) 12Stage B 6 1(16) 16Stage C 5 1(20) 11Stage D 23 2(8) 4Other GU. disease*: 87** 0(0)** 1BPH 57 0(0) -0.5Other benignGU. disease 22 0(0) -1Other malignantGU. disease 8 0(0) 3.5Non-GU. disease: 41** 2(4)** 3Benign 29 2(7) 9Malignant 12 0(0) -3______________________________________ *Overall mean NAI in control patients was 2. **A comparison of the LAI positive and negative patients in prostatic carcinoma and controls by Chi square, χ.sup.2 = 4.39, thus P < 0.05. .sup.+ The mean NAIs of prostatic carcinoma patients and control subjects were compared by Student's independent t test and is significant P < 0.02
Tube LAI assay and PGE 2 stimulation:
The NAI results using leucocytes with and without PGE 2 stimulation were compared. Of the 18 patients with prostatic carcinoma, 3 were positive without PGE 2 , and these patients remained LAI positive after PGE 2 stimulation. The other 14 prostatic carcinoma patients were LAI negative, but converted to positive with PGE 2 stimulation. Overall, that means 61% (11/18) of patients with prostatic carcinoma were LAI-positive. Another 35 control patients, 18 of whom had BPH, had their leucocytes stimulated with PGE 2 . Only one (3%) patient had a positive response with PGE 2 L stimulation; when retested a week later, this patient with BPH was LAI-negative. In the control group, the mean NAI of 1.2±1.5 without PGE 2 stimulation was not statistically significantly different (Student's dependent t test) from the mean NAI of 1.8±1.7 after PGE 2 stimulation. By contrast, the mean NAI of 28±0.4 for prostatic carcinoma patients with PGE 2 stimulation was significantly different from the mean NAI of 9.5±0.5 without PGE 2 stimulation. (Student's dependent t test, P 0.005).
Table 2 shows that 61% of patients with prostatic carcinoma were LAI-positive with PGE 2 stimulation, and this was significantly different (P<0.005) from the control subjects with 3% LAI-positive.
TABLE 2______________________________________LAI results with PGE.sub.2 stimulation in Prostatic Carcinomapatients and control patients. (+) NAI's No. No. (%)______________________________________Prostatic carcinoma: 18* 11(61)*Stage A 1 9(0)Stage B 3 3(100)Stage C 2 2(100)Stage D 12 6(50)Controls: 35* 1(3)*BPH 18 1(5)Other Disease 17 0(0)______________________________________ *A comparison of LAI positive and negative in prostatic carcinoma and controls by Chi square, χ.sup.2 = 19.8, thus P < 0.005
Organ-specific neoantigen:
Twenty patients with cancers other than prostate were tested for reactivity to the prostatic carcinoma extract, and none reacted. These patients had cancer of the kidney, bladder, testis, colon, breast and pancreas. Conversely, leucocytes from prostatic carcinoma patients were tested against extracts of bladder, colon, and pancrease carcinoma, and none reacted to these cancer extracts. No patients with BPH reacted to the prostatic carcinoma extract, and when the tissue from BPH was used as an extract, none of the LAI-positive prostatic carcinoma patients reacted to the BPH extract.
LAI and serum prostatic acid phosphatase (PAP) by radioimmunoassay:
In 13 prostatic carcinoma patients with various stages of the disease both PAP and LAI were performed in samples drawn the same day. The patients were divided into those with PAP within normal or above normal limits. In a group of 8 patients the mean PAP level of 2.7 ng/ml was within normal limits (N=1.2-5.7 ng/ml), and in this group the mean NAI was 19. By contrast, in the other group of 5 patients the mean PAP level was elevated to 13.4 ng/ml, and they had a mean NAI of 0.2.
When the patients age and their LAI response was compared, there was no difference in the LAI response of young or old patients.
Discussion
It has now been found that prostatic carcinoma patients express an antitumor immune response. Although few patients (14%) with prostatic carcinoma had a measureable antitumor response, their LAI-positive responses were statistically greater than the control subjects (1.5%) with or without BPH.
Because most patients with prostatic carcinoma seldom reacted in the tube LAI assay, the possible role of the patients, age and the tumor burden on the LAI response was examined. There was no difference in the LAI response of patients either young or old; thus, the patient's age did not explain the impaired antitumor response. When the bulk of tumor was estimated by measuring serum PAP by radioimmunoassay, patients with elevated values were observed to have low NAIs, demonstrating a lack of an antitumor immune response. On the other hand, patients with similar clinical stages of prostatic carcinoma, but low serum PAP levels, had high NAIs; hence, they expressed an antitumor immune response. The low incidence of antitumor immune responses detected in patients with prostatic carcinoma may reflect the affect of the tumor burden which, in most patients, is large enough to suppress the response by shedding tumor antigen, systemically.
There may be other reasons, of course, why patients with prostatic carcinoma seldom react in the tube LAI assay. It could be that the tumor extracts may not possess good antigenic activity. This possibility can not be entirely excluded, but tumor from two different sources gave similar results. Moreover, if the antigenic activity of the extracts was poor, it seems unlikely that PGE 2 stimulation of the leucocytes would have intensified the LAI response.
It seems, therefore, that the impaired LAI response of prostatic carcinoma patients reflects a functional defect in the responding leucocytes. This is supported by the fact that 61% of patients in the above study with prostatic carcinoma showed a positive LAI response after PGE 2 leucocyte stimulation. The PGE 2 stimulation was specific, for only 3% of controls were LAI positive. Also the mean NAI of control subjects did not change after PGE 2 stimulation, but the mean NAI of prostatic carcinoma patients rose dramatically.
PGE 2 , an extracellular mediator, binds to cell-surface receptors that engages and activates the adenylate-cyclase enzyme to enhance intracellular levels of cyclic 3',5'-adenosine monophosphate (cAMP). How the raised intracellular levels of cAMP restore leucocyte antitumor reactivity is not known, at this moment.
Analogous to other systems, in particular the mast cell, it seems probable that the cytophilic antitumor antibody on the membrane of leucocytes of prostatic carcinoma patients is cross-linked by antigen which is transduced into information useful to the cell. The transduction appears to involve the opening of calcium channels in the cell membrane, allowing calcium to enter the cell; this affects the polarization of the cell and may be responsible, in part, for the phenomenon of LAI. Increased intracellular levels of cAMP inhibit calcium gate formation, allowing the cell membrane to return to its normal polarized state. It seems possible that leucocytes from prostatic carcinoma patients, having encountered repeatedly tumor antigen in vivo, already have altered membrane potential, and the PGE 2 stimulation, by raising intracellular cAMP, inhibits calcium entry and helps the cell membrane to rapidly return to its normal polarized state. So when the leucocytes bind again tumor antigen in vitro, the transduction will open calcium channels, and the rise in free calcium in the cell will act, once more, to stimulate programmed cellular events; these events, including the changing membrane potential of the cells, mediate the phenomenon of LAI.
Bhatti et al., J. Retic. Soc. 25, 389 (1979); Eur. J. Cancer 15, 133 (1979) and Evans et al., Proc. R. Soc. Med. 70, 417 (1977) have reported that PBL of 77% and 89% of prostate carcinoma patients reacted prostatic carcinoma extracts in the tube LAI assay. The reason why our results are different is not clear. But Bhatti et al. seem to have calculated the results of individual patients on the basis of incubating cells with one antigen rather than comparing leucocyte non-adherence of each patient to the specific and nonspecific antigens. It is believed to be essential, however, to compare the difference in leucocyte non-adherence to the specific and nonspecific tumor extracts because leucocytes from advanced cancer patients, having already encountered tumor antigen in vitro, show enhanced non-adherence to glass with specific but also to nonspecific antigens.
The cancer antigen expressed by the prostate carcinoma is an organ-specific neoantigen, for patients with carcinoma other than prostate did not react to the prostatic carcinoma, nor did prostatic carcinoma patients react to extracts of other carcinomas. The antigen does not seem to be a normal tissue antigen, but is a neoantigen; for prostatic carcinoma patients did not react to an extract of benign prostatic hyperplasia, and patients with BPH showed no reactivity to prostatic carcinoma extracts. This differs from the findings of Avid et al., Urology 5, 122 (1975).
In the present study, more patients with early carcinoma showed a positive LAI response than did patients with late carcinoma, but the difference was not statistically significant due to the small number of patients responding in both groups.
In summary, prostatic carcinoma patients seldom react in the tube LAI assay. These patients may have a sufficient bulk of carcinoma, whether clinically detectable or not, to release systemically an excess or tumor antigen. This impairs the detection of the host's antitumor response in vitro because the leucocytes have already bound tumor antigen in vivo. Because PGE 2 has the ability to reverse the functional defect of the leucocytes produced by the circulating tumor antigen, it now makes it possible to detect an antitumor immune response in a greater number of patients with prostatic carcinoma.
It is understood that the discussion concerning the scientific theories upon which this aspect of the present invention is believed to be based is for purposes of illustration and exemplification only and should not be considered limiting in any way.
EXAMPLE 2
The LAI procedure of Example 1 was repeated with samples from prostatic carcinoma patients using a preincubation with a solution comprising 10 -5 .5 M PGE 2 and 10 -5 M aminophyllin provided mean NAI values above 60.
EXAMPLE 3
The LAI procedure of Example 1 was repeated with samples from prostatic carcinoma patients using a preincubation with a solution comprising 10 -5 M d,l-4-(3-isopropoxy-4-methoxybenzyl)-2-imidazolidinone provided mean NAI values above 65.
EXAMPLE 4
The LAI procedure of Example 1 was repeated with samples from prostatic carcinoma patients using a preincubation with a solution comprising 10 -6 M nat. 11R-methyl-16R-fluoro-15R-hydroxy-9S-hydroxyprosta-cis-6-trans-13-dienoic acid provided mean NAI values above 65. However, similar tests run with nat. 11R methyl-16R-fluoro-15R-hydroxy 9-oxoprosta-cis-6-trans-13-dienoic acid at concentrations of 10 -6 M, 10 -7 M, 10 -8 M, 10 -9 M and 10 -10 M yielded mean NAI values below 30 in all cases thus indicating that the latter compound was inactive.
EXAMPLE 5
The LAI procedure of Example 1 was repeated with samples from prostatic carcinoma patients using a preincubation with a solution comprising 10 -7 M nat. 11R-methyl-16-R-fluoro-9,15-dioxoprosta-cis-5-trans-13-dienoic acid provided mean NAI values above 55. Use of 10 -6 M in parallel runs provided mean NAI values below 30. | 4y
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional Application of U.S. patent application Ser. No. 10/748,610, filed Dec. 30, 2003.
FIELD OF THE INVENTION
[0002] The present invention relates to a graft for use with a stent in body lumens. More specifically, the present invention relates to a graft adapted to be secured to a stent surrounding the graft.
BACKGROUND OF THE INVENTION
[0003] A graft is typically used in conjunction with a stent to provide a prosthetic intraluminal wall, e.g., in the case of a stenosis or aneurysm, to provide an unobstructed conduit for blood in the area of the stenosis or aneurysm. A stent-graft may be endoluminally deployed in a body lumen, a blood vessel for example, at the site of a stenosis or aneurysm by so-called “minimally invasive techniques” in which the stent-graft is compressed radially inwards and is delivered by a catheter to the site where it is required, through the patient's skin, or by a “cut down” technique at a location where the blood vessel concerned is accessible. When the stent-graft is positioned at the correct location, the stent-graft is caused or allowed to re-expand to a predetermined diameter in the vessel.
[0004] Some early stent-grafts were manufactured by bonding the graft material to the stent frame with an adhesive, e.g., Corethane®. However, such an adhesive alone may not be sufficient to secure the graft to the stent during loading, as the graft material may peel away (i.e., separate) from the stent. Suture ties may also be utilized to fix the graft to the stent. However, suture attachment of the graft to the stent may create holes throughout the graft resulting in porosity which may be undesirable. For these and other reasons, improvements in securing a graft to a stent may have significant utility as compared to prior stent-graft combinations.
SUMMARY OF THE INVENTION
[0005] According to one aspect of this invention, a graft is adapted to be secured to a stent surrounding the graft in a novel way. The graft, typically tubular, includes an inner layer of a non-porous material, and an outer layer typically of knitted, woven, or braided material laminated to the inner layer. The graft further includes a plurality of fastening elements adapted to be secured to a stent surrounding the graft. An underside of each fastening element is fixed between the inner layer and the outer layer of the graft.
[0006] According to another aspect of this invention, a method of making a non-porous graft, and a stent-graft using that graft, is provided. A plurality of fastening elements are secured to an outer layer typically of knitted, woven, or braided material along a length of the outer layer, wherein the fastening elements extend outwardly from the outer layer. An inner layer of non-porous material is placed within the outer layer such that an underside of each fastening element is positioned between the inner layer and the outer layer. The outer layer is laminated to the inner layer to form the non-porous graft, which is then placed within a surrounding graft. The fastening elements are then secured to the stent.
[0007] The fastening elements may comprise loops which extend through openings in the stent and are adapted to secure the graft to the stent by a mating element, such as a linear element (or suture) which passes through each of these loops and secures them, optionally with a knot, to a structural part of the stent.
[0008] The resultant stent-graft may be used to provide a fluid passage through a body lumen. It may also be adapted for endoluminal placement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a plan view of a tubular graft including a plurality of fastening elements in accordance with the present invention;
[0010] FIG. 2A is a plan view of a non-porous tubular stent-graft including a plurality of fastening elements secured to a stent by a plurality of looped locking elements in accordance with the present invention;
[0011] FIG. 2B is a detail view of a fastening element secured to an element of the stent by a looped locking element illustrated in FIG. 2A ;
[0012] FIG. 3 is a plan view of a non-porous tubular stent-graft including a plurality of fastening elements secured to a stent by a linear locking element in accordance with the present invention; and
[0013] FIG. 4 is a cross-sectional view of the non-porous tubular graft of FIG. 1 , illustrating an outer layer laminated to an inner layer and a fastening element fixed between the layers.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims without departing from the invention.
[0015] Referring specifically to FIGS. 1-4 , there is shown a tubular graft 10 (best seen in FIG. 1 ) adapted to be secured to a stent 12 surrounding graft 10 in different ways (as illustrated in FIGS. 2A and 3 ). Stent 12 includes a plurality of structural members, four of which are identified in FIG. 2B as 12 A, B, C, and D. FIG. 4 is a cross-sectional expanded view of graft 10 illustrating an inner layer 14 of a non-porous material, and an outer layer 16 of knitted, woven, or braided material laminated to inner layer 14 . Graft 10 further includes a plurality of fastening elements 18 (only one of which is seen in FIG. 4 ) adapted to be secured on an outer surface 20 of stent 12 surrounding graft 10 . An underside 22 of each fastening element 18 is fixed between inner layer 14 and outer layer 16 . A plurality of fastening elements 18 may be distributed lengthwise along the length of graft 10 , as shown in FIGS. 1, 2A , and 3 , and/or circumferentially about graft 10 (not shown).
[0016] Fastening elements 18 extend outwardly from outer layer 16 , as illustrated in FIG. 4 . Non-porous inner layer 14 reduces or minimizes the porosity of graft 10 , thus compensating for any such porosity in outer layer 16 . Fastening elements 18 are retained between outer layer 16 , which is laminated to inner layer 14 , sealing underside 22 of each fastening element 18 between outer layer 16 and inner layer 14 . The finished assembly remains non-porous, resulting in a non-porous graft 10 .
[0017] Referring to FIG. 2A , the exemplary configuration illustrates graft 10 attached to an inside surface of stent 12 with fastening elements 18 projecting through stent 12 and a plurality of looped locking elements 24 , shown in greater detail in FIG. 2B , securing fastening elements 18 to stent 12 , thereby securing graft 10 to stent 12 . In this embodiment, each locking element 24 is knotted around both a fastening element 18 and an element or structural component of stent 12 to attach graft 10 to stent 12 . FIG. 2B is a detail view of a fastening element 18 secured to an element 12 A of stent 12 by a looped locking element 24 . Alternatively, a particular fastening element 18 may be secured to any one or more of elements 12 B, 12 C, or 12 D of stent 12 by looped locking element 24 .
[0018] As shown in FIG. 2B , fastening elements 18 may comprise D-shaped loops, the flat side of which is trapped between inner layer 14 and outer layer 16 , with the remainder of the loop projecting outwardly through outer layer 16 .
[0019] Similar to FIG. 2A , the exemplary configuration represented in FIG. 3 illustrates graft 10 attached to an inside surface of stent 12 with fastening elements 18 projecting through stent 12 . However, instead of utilizing looped locking elements 24 as a means for securing fastening elements 18 to stent 12 , a linear locking element 26 may be looped through each fastening element 18 and secured to the stent 12 independently of its connection to the fastening elements 18 . More specifically, a linear locking element 26 may be threaded and looped through each fastening element 18 while remaining along an outside surface of stent 12 . The end points of linear locking element 26 are secured to stent 12 , thereby attaching graft 10 to stent 12 .
[0020] Alternatively, a linear locking element 26 may be threaded through (not looped through) fastening elements 18 and secured to stent 12 at at least two points along a length of stent 12 (not shown). In other words, a linear locking element 26 may be threaded through fastening elements 18 while remaining along an outside surface of stent 12 , with each end of linear locking element 26 knotted around an element 12 A, 12 B, 12 C, or 12 D of stent 12 to attach graft 10 to stent 12 .
[0021] The shape of the fastening elements 18 is not limited to a D-shaped ring, as illustrated in FIG. 4 . Alternatively, fastening elements 18 may be round, square, triangular, or any other shape suitable for engagement with locking elements by which the graft 10 , through its fastening elements 18 , is secured to a stent 12 which surrounds it.
[0022] A further embodiment of the present invention includes a plurality of fastening elements, which are an integral part of outer layer 16 , extending outwardly from outer layer 16 disposed along the length and/or circumference of outer layer 16 of tubular graft 10 . In other words, each fastening element is not a distinct component from outer layer 16 as illustrated in FIG. 4 . Instead, the fastening elements are part of the material of outer layer 16 , i.e., loosely knitted, woven, or braided strands of material that form loops to act as fastening elements. At least some of the fastening elements are adapted to be secured on outer surface 20 of stent 12 surrounding graft 10 . The configurations of this embodiment with respect to means for securing the fastening elements to stent 12 (i.e., looped locking elements 24 or a linear locking element 26 ) are essentially the same as those of the embodiment of graft 10 comprising fastening elements 18 described previously herein with reference to FIGS. 1-3 .
[0023] An exemplary material for forming inner layer 14 of graft 10 is expanded polytetrafluoroethylene. The present invention, however, is not limited to polytetrafluoroethylene, and may include any material that offers the desired non-porous property of inner layer 14 . The material of outer layer 16 may be a woven or knit polyester. The present invention, however, is not limited to polyester, and may include any knitted, woven, or braided material suitable for lamination to inner layer 14 . Furthermore, the material of outer layer 16 is not limited to one that is porous, and may include any non-porous material suitable for lamination to inner layer 14 .
[0024] Fastening elements 18 and/or locking elements 26 may comprise conventional suture material. Other materials may be used as well, however, and may comprise, for example, wire or plastic. One or both of the fastening element material and the locking element material may comprise, in whole or in part, a radiographically differentiable material.
[0025] While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a thin film semiconductor device and, more particularly, to a thin film semiconductor device which can be also suitably used as a photoelectric converting device an image processing apparatus such as facused simile, digital copying apparatus, image reader, or the like.
2. Related Background Art
A thin film semiconductor made of a non-monocrystalline semiconductor, particularly, non-monocrystalline silicon (polysilicon, crystallite silicon, and amorphous silicon) is suitably used as a photoelectric converting device which can be preferably used as a thin film semiconductor device in a photoelectric converting device having a large area or a long length. As a photoelectric converting device using a thin film semiconductor, there are two kinds of devices such as primary photo-current type (photo-diode type) device and secondary photo current type device. Although the primary photo current type is a photoelectric converting device to extract electrons and holes generated by the incident light and photo-electrically convert it, there is a problem such that a photo-current which can be taken out as an output is small. On the other hand, according to the secondary photo-current type photoelectric converting device, since a larger photo current (secondary photo-current) can be obtained as compared with that of the primary photo-current type photoelectric converting device, it can be applied to apparatuses in a wider range and so attention is paid to it.
FIG. 1 is a schematic constructional diagram for explaining an example of the secondary photo current type photoelectric converting device. In FIG. 1, reference numeral 1011 denotes an insulative substrate such as glass or the like; 1012 a photo-conductive semiconductor layer made of CdS-Se, amorphous silicon hydride (hereinafter, abbreviated to "a-Si:H") formed by a plasma CVD method or the like, etc.; 1013a and 1013b impurity layers for ohmic contact; and 1014a and 1014b electrodes. In the above construction, by applying a voltage across the electrodes 1014a and 1014b, a large secondary photo-current flows and is photoelectrically converted when the light enters from the side of the substrate 1011 or the side of the electrodes 1014a and 1014b.
Further, a photoelectric converting device of the thin film transistor type having auxiliary electrodes to stabilize and improve the characteristics (photo-current, dark current, etc.) is proposed. FIG. 2 is a schematic constructional diagram of a thin film transistor type photoelectric converting device having auxiliary electrodes. In FIG. 2, the same component elements as those shown in FIG. 1 are designated by the same reference numerals. In FIG. 2, reference numeral 1015 denotes a transparent or opaque gate electrode and 1016 indicates a gate insulative layer made of SiN x or the like and formed by a plasma CVD method or the like.
Further, a complete contact type photo sensor (photoelectric converting device) using the thin film transistor type photoelectric converting device of FIG. 2, a thin film transistor, and the like is proposed (JP-A-61-26365). FIG. 3 shows an example of such a circuit. FIG. 3 relates to the case of a sensor array having nine thin film transistor type photoelectric converting sections. In the diagram, one block is constructed by every three of thin film transistor type photoelectric converting sections E 1 to E 9 . Thus, three blocks are formed by the converting sections E 1 to E 9 . The sensor array is constructed by those three blocks. Capacitors C 1 to C 9 and switching transistors T 1 to T 9 are respectively connected to the converting sections E 1 to E 9 in correspondence thereto. Individual electrodes of the photoelectric converting sections E 1 to E 9 are connected to corresponding proper ones of common lines 3102 to 3104 through the switching transitors T 1 to T 9 . In more detail, the first switching transistors T 1 , T 4 , and T 7 of each block are connected to the common line 3102. The second switching transistors T 2 , T 5 , and T 8 of each block are connected to the common line 3103. The third switching transistors T 3 , T 6 , and T 9 of each block are connected to the common line 3104. The common lines 3102 to 3104 are connected to an amplifier 3105 through switching transistors T 10 to T 12 .
Gate electrodes of switching transistors ST 1 to ST 9 are commonly connected every block in a manner similar to the gate electrodes of the switching transistors T 1 to T 9 and are connected to parallel output terminals of a shift register 3109 every block. Therefore, the switching transistors ST 1 to ST 9 are sequentially turned on every block by a shift timing of the shift register 3109.
In FIG. 3, the common lines 3102 to 3104 are respectively connected to the ground through capacitors C 10 to C 12 and to the ground through switching transistors CT 1 to CT 3 . A capacitance of each of the capacitors C 10 to C 12 is set to be sufficiently larger than that of each of the capacitors C 1 to C 9 Gate electrodes of the switching transistors CT 1 to CT 3 are commonly connected to a terminal 3108. That is, by applying a high level signal to the terminal 3108, the switching transistors CT 1 to CT 3 are simultaneously turned on, so that the common lines 3102 to 3104 are connected to the ground. Further, the photoelectric converting sections E 1 to E 9 have gate electrodes G 1 to G 9 .
FIG. 4 is a partial plan view of a one-dimensional complete contact sensor array formed on the basis of the circuit diagram shown in FIG. 3. In the diagram, reference numeral 3111 denotes a matrix-shaped wiring portion comprising the common lines 3102 to 3104 and the like; 3112 indicates a thin film transistor type photoelectric converting section; 3113 a charge accumulating section comprising the capacitors C 1 to C 9 ; 3114 a transfer switch which is constructed by the switching transistors T 1 to T 9 and uses thin film transistors having the same structure as that of the photoelectric converting section; 3115 a discharge switch which comprises the switching transistors ST 1 to ST 9 and uses thin film transistors having the same structure as that of the photoelectric converting section; 3116 an extension line to connect a signal output of the transfer switch 3114 to a signal processing IC: and 3117 a load capacitor which comprises the capacitors CT 1 to CT 3 and is used to accumulate the signal charges which have been transferred by the transfer switch 3114 and to read out the signal charges.
FIG. 5 is a cross sectional view taken along the line A--A' in FIG. 4. As will be obviously understood from FIG. 5, all of the thin film transistor type photoelectric converting section 3112, charge accumulating section 3113, transfer switch 3114, discharge switch 3115, matrix-shaped wiring section 3111, load capacitor 3117, and the like have a common construction in which a metal (gate electrode 1015 in the photoelectric converting section), an insulative layer (gate insulative layer 1016 in the photoelectric converting section), a photoconductive semiconductor layer (1012 in the photoelectric converting section), ohmic contact layers (1013a and 1013b in the photoelectric converting section), and metals (1014a and 1014b in the photoelectric converting section) are formed on the substrate 1011 in accordance with this order.
The sensor array shown in FIGS. 4 and 5 as mentioned above has the common construction in order to reduce the manufacturing costs by simultaneously manufacturing the photoelectric converting section and the drive circuit section. Particularly, when there is a high fine image reading request, the number of pixels must be increased, so that the drive circuit section which operates at a high speed is needed. However, when the thin film transistor as a thin film semiconductor device of the drive circuit section is made of a semiconductor material of a-Si:H, a mobility of the carrier lies within a range from 0.1 to 0.5 cm 2 ·C --1 ·S --1 and is not enough large. Consequently, there is a limitation in the charge transfer ability. To improve the charge transfer ability, in general, a size of thin film transistor as one of the thin film semiconductor devices is enlarged, the number of drive circuit sections is set to two, or the like. However, the size of the photoelectric converting apparatus is consequently enlarged and the manufacturing,costs are also increased. Therefore, it is desired to realize a photoelectric converting apparatus in which the size is not enlarged and the costs are low and which is suitable for miniaturization and has a drive circuit section having a high enough transfer ability.
SUMMARY OF THE INVENTION
The invention is made in consideration of the above problems and it is an object of the invention to provide a photoelectric converting apparatus having a drive circuit section, in which a semiconductor layer comprising a crystallite layer and an amorphous layer is used as a semiconductor layer or a photoconductive semiconductor layer, so that the semiconductor layer not only has good performance as a semiconductor device but also maintains good performance as a photoelectric converting section, a thin film transistor and the like of the drive circuit section can be formed by a construction which is common to the photoelectric converting section, the costs are low, the size is not enlarged, and a sufficiently high transfer ability is provided. The above object of the present invention can be accomplished by a thin film semiconductor apparatus comprising at least: an insulative layer; a semiconductor layer provided in contact with the insulative layer; first and second electrodes provided in contact with the semiconductor layer; and a third electrode provided via the insulative layer, wherein the semiconductor layer is formed by a crystallite layer whose average grain diameter lies within a range from 50 to 350 Å and an amorphous layer.
With the above semiconductor structure, a mobility of carriers is high and a sufficiently high charge transfer ability can be obtained. As mentioned above, the average grain diameter of the crystallite layer in the invention lies within a range from 50 to 350 Å in consideration of the balance between the carrier mobility and the characteristics of the apparatus, ease in manufacturing, and the like. A thickness of crystallite layer is preferably set to a value within a range about from 500 to 2000 Å in consideration of an effective transfer of charges.
According to the invention, the crystallite layer of the semiconductor layer can be arranged on the insulative layer side. A material containing at least silicon and hydrogen can be used as a semiconductor layer. At least the crystallite layer of the semiconductor layer can be formed by alternately performing many times the step of depositing a non-monocrystalline layer and the step of irradiating a hydrogen plasma on the deposited non-monocrystalline layer. A second insulative layer is provided in contact with the first and second electrodes provided in contact with the side of the semiconductor layer which faces the insulative layer. A fourth electrode can be provided in contact with the second insulative layer. In this case, the crystallite layer of the semiconductor layer can be also arranged on the insulative layer side, that is, the above described second insulative layer side.
The invention can be also obviously applied to a photoelectric converting apparatus (device) using the semiconductor layer as a photoconductive semiconductor layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic constructional diagram for explaining an example of a prior art converting device;
FIG. 2 is a schematic constructional diagram for explaining an example of a prior art photoelectric converting device;
FIG. 3 is a circuit diagram of a prior art photoelectric converting apparatus;
FIG. 4 is a partial plan view of a contact sensor array of the prior art circuit of FIG. 3;
FIG. 5 is a cross sectional view taken along the line A--A' of the contact sensor array of FIG. 4;
FIGS. 6, 10, and 12 are schematic constructional diagrams for explaining examples of a photoelectric converting devices according to the invention, respectively;
FIG. 7 is a conceptional diagram of a plasma CVD apparatus used to form the photoelectric converting device of the invention;
FIG. 8 is a gas introducing timing diagram in the plasma CVD apparatus in the formation of the photoelectric converting device of the invention;
FIGS. 9, 11, and 13 are diagrams showing characteristics of the photoelectric converting devices, respectively; and
FIG. 14 is an installation diagram of a contact photo sensor array using the photoelectric converting device of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodimetns of the present invention will be described hereinbelow with reference to the drawings.
Embodiment 1
FIG. 6 is a schematic constructional diagram of a photoelectric converting device of the invention. In the diagram, reference numeral 1011 denotes the substrate; 1016 the insulative layer; 1015 the third electrode (gate electrode); 1014a the first electrode (drain electrode); 1014b the second electrode (source electrode); 1013a and 1013b ohmic contact layers; and 1012 the photoconductive semiconductor layer. The photoconductive semiconductor layer 1012 has a double layer structure comprising: the a-Si:H layer 1012a on the side of the drain electrode 1014a and source electrode 1014b;a nd the crystalline layer 1012b on the side of the insulative layer 1016.
FIG. 7 is a constructional conceptional diagram for explaining an example of a plasma CVD apparatus used in manufacturing of the photoelectric converting device of the embodiment. In FIG. 7, reference numeral 70 denotes a reaction chamber; 11 a substrate in which functional layers such as a photoconductive semiconductor layer and the like are formed on the surface; 71 an anode electrode having a heater (not shown); 72 a cathode electrode; 73 a high frequency power source of 13.56 MHz; 74 an exhaust pump; 75 an SiH 4 gas introducing tube; 76 an H 2 gas (containing the Ar gas) introducing tube; 77 a microwave source of 2.45 GHz and a microwave applicator; and V 1 and V 2 valves to control the SiH 4 gas and H 2 gas, respectively. The valves V 1 and V 2 are connected to a computer to accurately control the opening/closing times.
The photoelectric converting device of the embodiment is manufactured in the following manner.
(1) A Cr layer having a film thickness of 0.1 μm is deposited onto the glass substrate 1011 (#7059 made by Corning Glass Works Co., Ltd.) by a sputtering method and is patterned into a desired pattern, thereby forming the gate electrode 1015.
(2) The substrate 1011 is set into the ordinary plasma CVD apparatus and a temperature of substrate is set to 350° C. After that, the SiH 4 gas, NH 3 gas, and H 2 gas are introduced at desired mixture ratios and the layer of SiN x :H is deposited, thereby forming the insulative layer 1016 having a film thickness of 3000 Å.
(3) Subsequently, the photoconductive semiconductor layer 1012 is deposited by the following procedure by using the plasma CVD apparatus shown in FIG. 7.
1 First, the substrate 1011 is set, the inside of the reaction chamber 70 is exhausted up to a predetermined pressure by the exhaust pump 74, and the substrate 1011 is simultaneously heated up to 340° C. by the heater (not shown).
The introducing timing of the SiH 4 gas and H 2 gas are controlled as shown in FIG. 8. That is, one unit (time t A ) having a time t 1 to deposit the film and a time t 2 to irradiate an H 2 plasma is repeated. For the film depositing time t 1 , both of the valves V 1 and V 2 are open, so that the SiH 4 gas, Ar gas, and H 2 gas are fed into the reaction chamber. The SiH 4 gas is set to 10 SCCM, the H 2 gas is set to 10 SCCM, and a pressure in the reaction chamber is adjusted to 0.1 Torr by the Ar gas. In this instance, a dpositing speed is set to about 3 Å/sec. A thickness of film which is deposited for the time t 1 is set to about 5 Å. For the H 2 plasma irradiating time t 2 , the valve V 1 is closed, the valve V 2 is opened, and the H 2 plasma is irradiated. A quality of film deposited for the time t 1 changes in dependence on the H 2 plasma irradiating time t 2 . Particularly, it has been found that an amount of H contained in the film changes and, when the time t 2 is set to a value longer than 80 seconds, a crystallite layer is formed. In the embodiment, the crystallite layer 1012b having a film thickness of 1000 Å is formed on the insulative layer 1016 side by alternately repeating the processes for the above times t 1 and t 2 a number of times.
The substrate is cooled up to 250° C. After that, the SiH 4 gas is set to 10 SCCM, the H 2 gas is set to 10 SCCM, the supply of the Ar gas is stopped, and the inside of the reaction chamber is set to 0.5 Torr, thereby depositing the a-Si:H layer 1012a having a film thickness of 4000 Å.
(4) The substrate is set into the ordinary plasma CVD apparatus and an ohmic contact layer having a film thickness of 1500 Å is formed by using the SiH 4 gas, PH 3 gas, and H 2 gas.
(5) Lastly, an Al layer having a thickness of 8000 Å is formed by a sputtering method and is patterned together with the above ohmic contact layer, thereby forming the ohmic contact layers 1013a and 1013b, drain electrode 1014a, and source electrode 1014b.
To examine the fundamental characteristics of the thin film transistor formed as mentioned above, a voltage within a range from -10 to 20 V is applied to the gate electrode 1015, a voltage of 1 V is applied to the drain electrode 1014a, and a voItage of 0 V is applied to the source electrode 1014b, and currents flowing between the drain electrode 1014a and the source electrode 1014b in both the light irradiating mode and the light non-irradiating mode are measured. In FIG. 9 the ordinate axis indicates the current flowing between the drain electrode 1014a and the source electrode 1014b and the abscissa axis indicates a voltage V G of the gate electrode 1015. In FIG. 9, A and A' indicate characteristics of the thin film transistor according to the embodiment of the invention in both of the light irradiating mode and the light non-irradiating mode, respectively. B and B' show characteristics of the thin film transistor in both of the light irradiating mode and the light non-irradiating mode in the case where such a thin film transistor is formed by a method similar to the above method except that the step (3) of forming the crystallite layer 1012b among the steps (1) to (5) of forming the thin film transistor according to the embodiment of the invention and that the a-Si:H layer having a film thickness of 6000 Å is formed in the step of forming the a-Si:H layer 1012a. As shown in FIG. 9, when comparing the characteristics A' and B' in the light non-irradiating mode, in the case of the thin film transistor (shown by A') of the embodiment of the invention, the current (dark current) flowing across the source electrode and the drain electrode near the gate electrode voltage of 20 V is increased by tens of %. On the other hand, when comparing the characteristics A and B in the light irradiating mode, in both of the thin film transistor of the embodiment of the invention and the thin film transistor as a comparison example, similar currents (photo-currents) flowing across the source electrode and the drain electrode are obtained.
From FIG. 9, it will be understood that the charge transfer ability of the thin film transistor of the embodiment of the invention is improved as compared with the charge transfer ability of the thin film transistor as a comparison example because of an increase in current between the source and drain electrodes in the light non-irradiating mode. It will be also understood that the current between the source and drain electrodes in the light irradiating mode in a region of V g ≦0 V where a sufficiently large ratio between the photo-current and the dark current can be obtained in the thin film transistor of the embodiment of the invention is almost similar to that of the thin film transistor as a comparison example, so that the transistor of the embodiment can be also sufficiently used as a photoelectric converting section.
Embodiment 2
FIG. 10 is a schematic constructional diagram of a photoelectric converting device in which the charge transfer ability of the photoelectric converting device of the embodiment 1 is further improved. In the diagram, the same component elements as those in FIG. 6 are designated by the same reference numerals. In FIG. 10, reference numeral 1015b denotes a gate electrode and 1016b indicates a gate insulative layer made of SiN x or the like. The device of FIG. 10 differs from that of FIG. 6 with respect to the depositing of an a-Si:H layer 1012a and a crystallite layer 1012b of the photoconductive semiconductor layer 1012 and the position of the gate electrode 1015b.
The photoelectric converting device of the embodiment 2 is manufactured in the following manner.
(1) The step (1) is similar to the step (3) in the embodiment 1 except that the forming order of the a-Si:H layer 1012a and the crystallite layer 1012b is reversed and the substrate temperature when the crystallite layer 1012b is formed is set to 230° C.
(2) The step (2) is similar to the step (4) in the embodiment 1.
(3) The step (3) is similar to the step (5) in the embodiment 1.
(4) The substrate 1011 is set into the ordinary plasma CVD apparatus and the substrate temperature is set to 220° C. After that, the SiH 4 gas, NH 3 gas, and H 2 gas are introduced at predetermined mixture ratios and an SiN x :H layer is deposited, thereby forming the insulative layer 1016b having a film thickness of 3000 Å.
(5) Lastly, an ITO transparent layer having a film thickness of 2000 Å is formed by a sputtering method and is patterned, thereby forming the transparent gate electrode 1015b.
To examine the fundamental characteristics of the thin film transistor formed as mentioned above, a voltage within a range from -10 to 20 V is applied to the gate electrode 1015b, a voltage of 1 V is applied to the drain electrode 1014a, a voltage of 0 V is applied to the source electrode 1014b, and currents flowing between the drain electrode 1014a and the source electrode 1014b in the light irradiating mode and the light non-irradiating mode are measured. In FIG. 11, the ordinate axis indicates a current between the drain electrode 1014a and the source electrode 1014b and the abscissa axis shows a voltage V G of the gate electrode 1015b. In FIG. 11, A and A' indicate the characteristics of the thin film transistor of the embodiment of the invention in both the light irradiating mode and the light non-irradiating mode, respectively. B and B' indicate the characteristics of the thin film transistor as a comparison example in the light irradiating mode and the light non-irradiating mode, respectively, in the case where such a thin film transistor is formed by substantially the same forming method as the above method except that the step (1) of forming the crystallite layer 1012b among the steps (1) to (5) of forming the thin film transistor of the embodiment of the invention and that the a-Si:H layer having a film thickness of 6000 Å is formed in the step of forming the a-Si:H layer 1012a. As shown in FIG. 11, when comparing the characteristics A' and B' in the light non-irradiating mode, in the case of the thin film transistor of the embodiment of the invention, the current (dark current) flowing across the source and drain electrodes near the gate electrode voltage of 20 V is increased by about 1.5 digits. When comparing the characteristics A and B in the light irradiating mode, in both of the thin film transistor of the embodiment of the invention and the thin film transistor as a comparison example, the similar currents (photo-currents) flowing across the source and drain electrodes are obtained.
It will be understood from FIG. 11 that the charge transfer ability of the thin film transistor of the embodiment of the invention is improved as compared with the charge transfer ability of the thin film transistor as a comparison example due to a large increase in current flowing between the source and drain electrodes in the light non-irradiating mode. Since the current between the source and drain electrodes in the light irradiating mode in the thin film transistor of the embodiment of the invention is almost similar to that in the thin film transistor as a comparison example, it will be understood that the thin film transistor of the embodiment can be also sufficiently used as a photoelectric converting section.
Embodiment 3
FIG. 12 is a schematic constructional diagram of a photoelectric converting device in which the charge transfer ability of the photoelectric converting device of the embodiment 1 is further improved. In FIG. 12, the component elements similar to those shown in FIG. 6 are designated by the same reference numerals. In FIG. 12, reference numeral 1015a denotes a third electrode (gate electrode); 1015b the fourth electrode (gate electrode); and 1016 and 1016b gate insulative layers made of SiN x or the like. The device of FIG. 12 largely differs from the device of FIG. 6 with respect to the depositing positions of the a-Si:H layer 1012a and the crystallite layer 1012b of the photoconductive semiconductor layer 1012 and the presence or absence of the gate electrode 1015b.
The photoelectric converting device of the embodiment is manufactured in the following manner.
(1) The step (1) is similar to the step (1) of the embodiment 1.
(2) The step (2) is similar to the step (2) of the embodiment 1.
(3) The step (3) is similar to the step (3) of the embodiment 1 except that the forming order of the a-Si:H layer 1012a and the crystallite layer 1012b is reversed and the substrate temperature when the crystallite layer 1012b is formed is set to 230° C.
(4) The step (4) is similar to the step (4) of the embodiment 1.
(5) The step (5) is similar to the step (5) of the embodiment 1.
(6) The substrate 1011 is set into the ordinary plasma CVD apparatus and the substrate temperature is set to 220° C. After that, the SiH 4 gas, NH 3 gas, and H 2 gas are introduced at predetermined mixture ratios and an SiN x :H layer is deposited, thereby forming the insulative layer 1016b having a film thickness of 3000 Å.
(7) Lastly, an ITO transparent layer having a film thickness of 2000 Å is formed by a sputtering method and is patterned, thereby forming the transparent gate electrode 1015b.
To examine the fundamental characteristics of the thin film transistor formed as mentioned above, a voltage within a range from -10 to 20 V is applied to the gate electrode 1015b, a voltage of 1 V is applied to the drain electrode 1014a, a voltage of 0 V is applied to the source electrode 1014b, and currents flowing between the drain electrode 1014a and the source electrode 1014b in both of the light irradiating mode and the light non-irradiating mode are measured. The voltage of gate electrode 1015 is set to 0 V. The light enters from the direction on the side of the gate electrode 1015b. In FIG. 13, the ordinate axis indicates the current flowing between the drain electrode 1014a and the source electrode 1014b and the abscissa axis indicates the voltage V G of the gate electrode 1015b. In FIG. 13, A and A' indicate the characteristics of the thin film transistor of the embodiment of the invention in both the light irradiating mode and the light non-irradiating mode, respectively. B and B' indicate the characteristics of the thin film transistor as a comparison example in the light irradiating mode and the light non-irradiating mode, respectively, in the case where such a thin film transistor is formed by substantially the same method as the foregoing method except that the step (3) of forming the crystallite layer 1012b among the steps (1) to (7) of forming the thin film transistor of the embodiment of the invention is omitted and that the a-Si:H layer having a film thickness of 6000 Å is formed in the step of forming the a-Si:H layer 1012a. As shown in FIG. 13, when comparing the characteristics A' and B' in the light non-irradiating mode, in the case of the thin film transistor of the embodiment of the invention, the current (dark current) flowing between the source and drain electrodes near the gate electrode voltage of 20 V is increased by about 1.5 digits. When comparing the characteristics A and B in the light irradiating mode, in both of the thin film transistor of the embodiment of the invention and the thin film transistor as a comparison example, the similar currents (photo-currents) flowing between the source and drain electrodes are obtained.
It will be understood from FIG. 13 that the charge transfer ability of the thin film transistor of the embodiment of the invention is improved as compared with the charge transfer ability of the thin film transistor as a comparison example due to a large increase in current across the source and drain electrodes in the light non-irradiating mode. Since the current flowing between the source and drain electrodes in the light irradiating mode in the thin film transistor of the embodiment of the invention is almost similar to that in the thin film transistor as a comparison example, it will be understood that the thin film transistor of the embodiment can be also be used as a photoelectric converting section.
Embodiment 4
A circuit as shown in FIG. 3 is constructed as a one-dimensional contact sensor array by using the photoelectric converting section comprising the thin film transistor formed in the second embodiment and the drive circuit section comprising such a thin film transistor or the like. In a manner similar to the embodiment 1, the various characteristics of the thin film transistor type photoelectric converting section are examined. Thus, the characteristics similar to those in the embodiment 1 were obtained. In the thin film transistor of the drive circuit section or the like, sufficient characteristics are shown and the charge transfer ability is improved by about one digit.
FIG. 14 is a cross sectional view showing a state in which the photoelectric converting device of the invention is installed as a one-dimensional complete contact type photo sensor array. In FIG. 14, an abrasion resistant layer 121 made of glass or the like is formed through a protective layer 120 over the photoelectric converting section and the drive circuit section. An original 123 is illuminated by a light source 122 such as a light emitting diode or the like from the back side of the translucent substrate 1011 such as glass or the like, thereby reading the original 123. It will be obviously understood that the photo sensor array using the photoelectric converting device of the invention can be also used as a one-dimensional contact type photo sensor array using an equal magnification image forming lens.
In the above embodiments, SiH 4 , H 2 , and the like are used as materials to form the thin film. However, the invention is not limited to those materials but can also use materials containing F or the like or materials containing gases having a chemical formula of SiH 2n+2 (n is an integer of 2 or more). As silicon used in the invention, in addition to materials comprising at least silicon and hydrogen, silicon materials containing, for instance, fluorine or the like and other materials can be used.
According to the invention as described above, since the semiconductor layer or photoconductive semiconductor layer comprising the crystallite layer and the amorphous layer is used, it has good performance as a semiconductor apparatus and good performance is maintained as a photoelectric converting section. Therefore, there is provided a photoelectric converting apparatus having a drive circuit section in which a thin film transistor or the like of the drive circuit section can be formed by a construction which is common to that of the photoelectric converting section, the costs are low, the size is not enlarged, and a high enough transfer ability is obtained. | 4y
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TECHNICAL FIELD
The invention relates to a gas flow valve.
BACKGROUND OF THE INVENTION
Conventional gas flow valves hitherto comprise one or more shutoff bodies between the gas inlet and the gas outlet which, depending on their position, permit a gas flow through the valve or interrupt the flow path. These moving shutoff bodies need to have a correspondingly close tolerance so that no leakage currents occur in the shutoff position of the valve. Conventional gas flow valves as usual hitherto are usually complicated to manufacture.
BRIEF SUMMARY OF THE INVENTION
The invention provides a gas flow valve of simple configuration. The gas flow valve according to the invention comprises at least one gas inlet, at least one gas outlet, flow path between said gas inlet and said gas outlet, a magnetic fluid in the valve arranged in the flow path and means for application of a magnetic field to the magnetic fluid. The magnetic fluid solidifies upon application of the magnetic field, interrupts the flow path from at least one gas inlet to at least one gas outlet gas-tight and permits gas flow when no magnetic field is applied.
Instead of operating with a moving sliding body or a separate shutoff body the gas flow valve in accordance with the invention operates with a magnetic fluid and has thus a very simple and rugged configuration subjected to no wear.
Magnetic fluids are stable dispersed systems containing modified magnetic particles a few nanometers in size as a dispersed phase. The dispersion medium used may be, for example, water, hydrocarbons or also vacuum and dispersion oils. By specifically altering the chemical composition a, variety of magnetic fluids can be produced, each of which can be optimized for the application in each case.
Hitherto, magnetic fluids have been used, for example, for magnetohydrostatic separation in which use is made of the buoyancy of non-metals in the magnetic fluid magnetically determined and dependent on the density and magnetic field gradient for the separation of non-metals. In addition, magnetic fluids are also used for sealing, mounting, damping and relieving the loads on shafts. In automotive engineering magnetic fluids serve, among other things, for adjusting the various damping requirements in vehicle suspension since differing degrees of hardness can be generated by magnetic fields differing in strength, resulting in differing viscosities of the magnetic fluid.
The present invention employs, however, the magnetic fluid for switching a gas valve by utilizing the change in viscosity of the magnetic fluid due to application of a magnetic field. When no magnetic field or merely a weak magnetic field is applied the magnetic fluid remains fluid and homogenous. In this condition, a gas can flow from the gas inlet through the fluid to the gas outlet, whereas by applying a sufficiently strong magnetic field the magnetic fluid changes from the fluid state to the solid state in which the gas is shut off by the solidified magnetic fluid. In addition, the magnetic fluid is attracted by the magnetic field, i.e. a shiftable magnet may be specifically put to use to shut off or open individual inlets or outlets. It is furthermore conceivable to apply a magnetic field of only medium strength by which the magnetic fluid does not totally shut off the gas flow, i.e. permitting a partial gas flow so that the gas volume flowing through the valve in accordance with the invention can be continuously adjusted.
Two different basic principles are possible for opening a gas inlet and/or gas outlet. According to the first principle it is provided for that the fluid level is adapted to the gas inlet and gas outlet so that when the gas inlet and gas outlet are open the gas flows through the fluid. According to the second principle the gas does not flow through the fluid when the valve is open. For this purpose it is provided for that for opening at least one gas inlet and/or one gas outlet the magnetic field acts on the magnetic fluid in such a direction and strength that the latter is displaced into the region of the gas inlet and/or gas outlet so that gas is able to flow directly from the gas inlet to the gas outlet without passing through the fluid. In this arrangement the magnetic field attracts or repels the fluid, the magnetic fluid being shifted so that the fluid surface is not horizontal but inclined.
The valve in accordance with the invention may be e.g. a 2/2-way valve. One embodiment of the invention provides for a pressure vessel between the gas inlet and the gas outlet which is filled at least in part by the magnetic fluid into which an inlet tube protrudes, a part of the inlet tube extending beyond the fluid level. This part of the inlet tube extending beyond the fluid level prevents fluid from flowing out of the pressure vessel via the inlet tube carrying the gas.
The inlet tube may be configured bow-shaped and protrude into the fluid by its inlet end from above or also additionally extend from below through a base surface area and a section of the pressure vessel filled with fluid up to above the fluid level and from there downwards again into the fluid. In addition, it is possible to guide the inlet tube through an upper side of the pressure vessel into the fluid.
The pressure vessel is preferably cylindrical or cuboidal in shape and may be provided with a rounded under part, the gas outlet in this embodiment being provided on the upper side of the pressure vessel.
The magnetic field can be generated in various ways. In accordance with a first possibility a permanent magnet movable to and from the magnetic fluid may be provided which in accordance with a preferred embodiment surrounds the pressure vessel for example annularly and is shiftable parallel to the shell surface area of the latter from a non-actuated position into an actuated position. In the actuated position the permanent magnet surrounds at least in part the portion of the pressure vessel filled with magnetic fluid.
If the permanent magnet is shiftable at the shell surface area of the pressure vessel, a separate mounting having parallel guides for shifting the permanent magnet can be eliminated.
The second possibility of generating a magnetic field is to provide a switchable electromagnet, this too, surrounding preferably at least in part the portion of the pressure vessel filled with magnetic fluid. Accordingly, in the interior of the spool of the electromagnet, where the magnetic field is particularly strong, the magnetic fluid is also arranged.
In the case of a valve having a rounded lower part the magnet, which may be configured as a permanent magnet and also as an electromagnet, may be arranged arrestable continuously or in several positions to specifically interrupt or admit the gas flow in one or more suitably arranged inlets or outlets.
It has been found to be particularly favorable to add non-magnetic particles such as e.g. particles of plastics, rubber or of diamagnetic or paramagnetic metals such as copper or aluminum to the magnetic fluid which support switching the valve. The non-magnetic particles may, on the one hand, receive in the magnetic fluid a magnetic buoyancy depending on the density and magnetic field gradient and are thus displaced to the top edge of the magnetic fluid and, on the other, particles having no magnetic buoyancy may be provided which are pressed against each other due to the change in viscosity on application of a magnetic field. In any case by providing such non-magnetic particles an accelerated and improved shutoff effect of the valve is attained.
It is furthermore preferably provided for that tensides exist in the magnetic fluid which due to their molecular structure are surface-active and are employed as wetting agents, esters or fatty acids being particularly suitable in this respect.
Using a magnetic fluid for a gas flow valve is not restricted to merely a one-way valve, the invention also defining a 3/2 way and multiway gas flow valve, whereby several of the valves as described above may be connected to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a 2/2-way valve in the open condition incorporating an electromagnet in accordance with the invention,
FIG. 2 shows the valve of FIG. 1 in the closed condition,
FIG. 3 is a schematic illustration of the 2/2-way valve in the open condition incorporating a permanent magnet in accordance with a second embodiment of the invention,
FIG. 4 shows the valve of FIG. 3 in the closed condition,
FIG. 5 is a schematic illustration of a 3/2-way valve in the open condition incorporating two electromagnets in accordance with the invention,
FIG. 6 shows the valve of FIG. 5 in the closed condition,
FIG. 7 is a schematic illustration of a valve incorporating two electromagnets in accordance with the invention, with a mixing function in the switching position 1st gas inlet is open, 2nd gas inlet is closed,
FIG. 8 shows the valve of FIG. 6 in the inverse switching position 1st gas inlet is closed, 2nd gas inlet is open,
FIG. 9 shows the valve of FIGS. 7 and 8 in the switching position closed,
FIG. 10 shows the valve of FIGS. 7 to 9 in the switching position open,
FIG. 11 is a schematic illustration of a valve incorporating two electromagnets in accordance with a further embodiment of the invention, with a distributing function in the switching position 1st gas outlet is open, 2nd gas outlet is closed,
FIG. 12 shows the valve of FIG. 11 in the switching position 1st gas outlet is closed, 2nd gas outlet is open,
FIG. 13 shows the valve of FIGS. 11 and 12 in the switching position closed,
FIG. 14 shows the valve of FIGS. 11 to 13 in the switching position open,
FIG. 15 is a schematic illustration of a multiway valve incorporating an electromagnet in accordance with an additional embodiment of the invention in the partly closed condition as a side view and plan view,
FIG. 16 is a side view and plan view of the valve shown in FIG. 15 in the state with all gas inlets open.
FIG. 17 is a schematic illustration of a multiway valve incorporating an electromagnet with a filler tube via which the fluid level of the magnetic fluid can be regulated in accordance with the invention in the partly closed condition as a side view and plan view, and
FIG. 18 is a side view and plan view of the valve shown in FIG. 17 in the state with all gas inlets open.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 to 4 show a gas flow valve 1 configured as a 2/2-way valve.
In accordance with a first embodiment shown in FIGS. 1 and 2 a cylindrical pressure vessel 7 is provided which is partly filled with a magnetic fluid 3. Outside of the pressure vessel 7 an electromagnet 9 in the form of a spool surrounds the part of the pressure vessel 7 filled with fluid. The electromagnet 9 is connected to a voltage source via leads 10, making and breaking the connection of which depends on the position of a switch 12. The cylindrical shape of the pressure vessel enables the valve 1 as well as its electromagnet 9 annularly surrounding the pressure vessel 7 and adjoining the latter to be simply fabricated.
The inlet tube 11 extends through an opening in the shell surface area of the pressure vessel 7 into the magnetic fluid 3 and further bow-shaped above the fluid level 5 before finally protruding into the fluid 3 from above by its gas inlet 2. Due to part of the inlet tube 11 extending above the fluid level 5 no magnetic fluid 3 is able to flow from the pressure vessel 7 via the inlet tube 11. A gas outlet 6 is located on the upper side 8 of the pressure vessel 7.
The functioning of the valve 1 will now be explained with respect to the FIGS. 1 and 2. In FIG. 1 the switch 12 is shown in the open condition, i.e. the electromagnet 9 is not connected to the voltage source and no magnetic field is generated. In this condition the magnetic fluid 3 is in the liquid phase, non-magnetic particles 4 being utmost finely dispersed in the magnetic fluid 3. Water is employed as the dispersion medium for the magnetic particles present in the magnetic fluid 3. Since the magnetic fluid 3, as shown in FIG. 1, is present in its liquid phase gas is able to flow via the inlet tube 11 and the gas inlet 2 through the fluid 3. The portion of the interior of the pressure vessel 7 not filled with fluid 3 is filled with gas which is able to flow via the gas outlet 6 to a consumer.
If the valve 1 is to be closed, the switch 12, as shown in FIG. 2, must also be closed so that the electromagnet 9 creates a magnetic field which acts on the magnetic fluid 3. The magnetic field is thereby so strong that a change in viscosity of the magnetic fluid 3 and a phase transition from fluid to solid takes place. The non-magnetic particles present in the magnetic fluid 3, preferably in the form of elastomers, are selected such that they receive a magnetic buoyancy in this state in the fluid 3 and are forced to the fluid level 5 where they are pressed together to form an additional barrier layer. The solidified magnetic fluid 3 permits no flow of gas and totally interrupts the gas flow.
The further embodiment shown in the FIGS. 3 and 4 substantially corresponds to the embodiment explained heretofor except that instead of the electromagnet 9 a permanent magnet 19 is provided arranged vertically shiftable on the shell surface area of the pressure vessel 7 so that the shell surface area represents the mounting for the permanent magnet 19. Contrary to the embodiment described above the inlet tube 11 extends from below through a base surface area 13 of the pressure vessel 7 into the interior of the latter.
In the open position of the valve 1 as shown in FIG. 3 the permanent magnet 19 is arranged in the upper portion of the pressure vessel 7. In this arrangement the magnetic field generated by the latter is so far removed from the magnetic fluid 3 that it is too weak to translate the fluid 3 present in the liquid phase as shown in FIG. 3 into the solid phase or to attract it into portions having a stronger magnetic field.
When, however, the permanent magnet 19, as shown in FIG. 4, is shifted downwards so that it surrounds the part of the pressure vessel 7 filled with fluid 3, the actions in the fluid 3 as explained in conjunction with FIG. 2 occur and the valve 1 assumes its closed position. The tensides also present in the fluid 3 are surface-active and prevent a kind of agglomeration of non-magnetic particles.
It is also possible to configure valves 1 to incorporate both electromagnets 9 and permanent magnets 19.
FIGS. 5 and 6 show a gas flow valve 1 configured as a 3/2-way valve.
In accordance with this embodiment a cylindrical pressure vessel 7 is provided which is partly filled with a magnetic fluid 3. Protruding from above through openings in the upper side 8 of the pressure vessel 7 into this magnetic fluid 3 is a vent tube 14 and an inlet tube 11 having a gas inlet 2, a gas outlet 6 being located on the upper side 8 of the pressure vessel 7.
Outside of the pressure vessel 7 two electromagnets 9, 16 in the form of spools are arranged such that one surrounds the region of the gas inlet 2, the other the region of the gas inlet 23. The electromagnets 9 and 16 are connected via leads 10 and 22 respectively to the voltage sources (not shown), the circuits being closed or interrupted depending on the position of the switches 12, 21. Two of the possible four switching positions of the switches 12, 21 are made use of to achieve the 3/2-way valve, namely the switching position switch 12 open, switch 21 closed (FIG. 5) and the switching position switch 12 closed, switch 21 open (FIG. 6).
The functioning of the 3/2-way valve will now be explained with respect to the FIGS. 5 and 6. In FIG. 5 the circuit of the electromagnet 16 is closed, i.e. electromagnet 16 generates a magnetic field which attracts the magnetic fluid 3 into the region of the gas inlet 23 where it translates from the liquid phase into the solid phase. In this case too, the non-magnetic particles 4 dispersed in the liquid phase, as shown in FIG. 2, are displaced by the magnetic field outwards, i.e. to the fluid surface represented by the inclined fluid level 5, where they form an additional barrier layer. The solidified magnetic fluid 3 allows no flow of gas and totally seals off the vent tube 14. Between inlet tube 11 and gas outlet 6 the gas is able to flow unobstructed, valve 1 being open.
In the position shown in FIG. 6 the circuit of the electromagnet 9 is closed via the switch 12, whereas the circuit of the electromagnet 16 is broken by the switch 21. The electromagnet 9 generates a magnetic field which attracts the magnetic fluid 3 into the region of the gas inlet 2 so that the fluid there translates from the liquid phase into the solid phase. Here too, the same as in the switching position shown in FIG. 5, the barrier layer consists of non-magnetic particles 3. The gas inflow through the inlet tube 11 is totally interrupted, valve 1 is closed. Between gas outlet 6 and vent tube 14 gas is able to flow via the pressure vessel 7, however, i.e. valve 1 is vented.
The embodiment shown in FIGS. 7 to 10 corresponds substantially to the embodiment explained by way of FIGS. 5 and 6, here however, instead of the vent tube 14 a second inlet tube 15 protrudes from above into the magnetic fluid 3.
The two inlet tubes 11, 15 may be closed or opened or switched in common by a corresponding assigned magnetic field. The result is a valve 1 having a mixing function.
In accordance with FIG. 7 the inlet tube 15 is closed by the effect of the magnetic field of the electromagnet 16. Between the inlet tube 11 and the gas outlet 6 gas is able to flow unobstructed.
FIG. 8 shows the inverse function. In this case the inlet tube 11 is closed by the effect of the magnetic field of the electromagnet 9 and gas is able to flow unobstructed between inlet tube 15 and gas outlet 6.
In FIG. 9 the circuits of both electromagnets 9, 16 are closed. Due to the effect of the magnetic fields the magnetic fluid 3 is attracted in each case to the inlet tubes 11 and 15 sealing off the gas inlets 2 and 23 totally due to the actions in the magnetic fluid 3 as already described, valve 1 being closed. Part of the fluid 3 is displaced to the left-hand side of the pressure vessel 7 to close the gas inlet 23 by an inclined gas-tight fluid surface 5. The remaining other part of the fluid 3 is displaced to the right-hand side of the pressure vessel 7 where it closes off the gas inlet 2 by an inclined gas-tight fluid surface.
In FIG. 10 the switches 12 and 21 are open, i.e. the electromagnets 9 and 16 generate no magnetic fields. The magnetic fluid 3 is present in the liquid phase and allows gases to flow from both gas inlets 2, 23 to the gas outlet 6.
FIGS. 11 to 14 show an embodiment which substantially corresponds to the embodiment illustrated in FIGS. 7 to 10. Due to the change in the arrangement a valve 1 having a distribution function materializes. In this case the inlet tube 11 is arranged between two outlet tubes 17, 18 so that should no magnetic field be applied the gas inlet 2 and ends 24 and 25 of the outlet tubes 17 and 18 respectively protrude into the magnetic fluid 3.
In FIG. 11 closing the switch 21 closes the circuit of the electromagnet 16, whereas the circuit of the electromagnet 9 is open. The electromagnet 16 generates a magnetic field in the region of the end 24. Due to the effect of the magnetic field the magnetic fluid 3 is attracted into this region where it solidifies. The aforementioned inner actions seal off the gas outlet 17 totally, whereas gas from the inlet tube 11 is able to flow via the outlet tube 18 from the pressure vessel 7 without needing to flow through magnetic fluid.
FIG. 12 shows the inverse function of valve 1. In this case the outlet tube 18 is shut off by the magnetic field generated by the electromagnet 9. From the inlet tube 11 gas is able to flow via the outlet tube 17 from the pressure vessel 7.
In FIG. 13 the switches 12 and 21 are closed. The electromagnets 9 and 16 generate magnetic fields which attract the magnetic fluid 3 into the regions of the ends 24 and 25, the fluid translating into the solid phase. The two outlet tubes 17 and 18 are totally shut off by the inner actions in the magnetic fluid as already described, valve 1 being in the blocking function.
In FIG. 14 the circuits of the electromagnets 9 and 16 are open so that no magnetic field effects the magnetic fluid 3. As described in FIG. 1 gas is able to flow from the inlet tube 11 through the fluid 3 and outlet tubes 17, 18. In this case the gas is distributed to the two outlet tubes 17 and 18.
FIGS. 15 and 16 show a further embodiment of a valve 1 configured as a multiway valve having a mixing function comprising four inlet tubes 11, 15, 26 and 27 and a gas outlet 6. The way in which the valve 1 works corresponds substantially to that as already explained with respect to FIGS. 7 to 10. Shutting off or opening individual inlet tubes 11, 15, 26, 27 is done by means of the electromagnet 9 being horizontally rotatable at a hemispherical lower part 13' of the valve 1 about the vertical longitudinal axis of the pressure vessel 7 (cf arrow A) and/or being shiftably mounted about the lower end of the hemispherical lower part 13' oscillatingly (cf arrow B). The corresponding guidance of the electromagnet 9 is not shown. The electromagnet 9 can be arrested in several positions or even continuously so. Instead of the electromagnet 9 a permanent magnet may also be provided.
In accordance with FIG. 15 the annular electromagnet 9 is shiftably mounted by a guiding means (not shown) such that its magnetic field attains only the region of the gas inlet 2. Due to the effect of the magnetic field the solidified magnetic fluid 3 shuts off the inlet tube 15. If the fluid level 5 is brought to the fluid level 5a by replenishing the fluid 3 via a filler tube (not shown) further inlet tubes are shut off, these being in the example inlet tubes 26 and 27, depending on the fluid level 5a, the magnetic fluid 3 and the position of the electromagnet 9.
In the position shown in FIG. 16 the electromagnet 9 extends around the lower part 13' of the valve 1. In this horizontal basic setting all lower tube ends of the inlet tubes 11, 15, 26 and 27 lie in the region of its magnetic field. The switch 12 of the circuit is opened and no magnetic field acts on the magnetic fluid 3. As described above, in this case gas is able to flow from the inlet tubes 11, 15, 26 and 27 through the magnetic fluid 3 and through the gas outlet 6 from the pressure vessel 7 since valve 1 is totally opened. When, however, the switch 12 in this basic setting of the electromagnet 9 is closed, the magnetic fluid 3 solidifies due to the effect of the magnetic field of the electromagnet 9 as already described and seals off all inlet tubes 11, 15, 26 and 27 so that valve 1 is totally shut off.
FIGS. 17 and 18 show the gas flow valve 1 as has already been explained with respect to FIGS. 15 and 16. To change the fluid level 5 a gas-sealable filler tube 28 is introduced from above through the upper side 8 of the pressure vessel 7 sufficiently downwards so that it protrudes into the magnetic fluid 3 in the horizontal basic setting of the magnet 9. The filler tube 28 is connected to a pumping system (not shown) and permits a continuous change in function of the valve 1. Depending on the position of the electromagnet 9 and the filling level 5, one, two or three inlet tubes are thus sealed off.
It is also possible to configure valves incorporating both electromagnets 9 and additional permanent magnets 19.
The multiway valves as described above are characterized by a single pressure vessel being sufficient since the magnetic fluid is drawn into a strong magnetic field so that predetermined inlet or outlet tubes can be opened or closed. In addition to this, however, multiway valves may also be produced by several of the valves already described, connected to each other and switched via corresponding drilled passageways.
In addition at the input of each switch 12, 21 a potentiometer may be arranged with which the amperage applied to the electromagnet 9 or 19 can be continuously varied. Varying the amperage in turn varies the viscosity of the magnetic fluid 3 so that this too is continuously variable to allow more or less gas to flow through the valve 1, thus achieving a continuously adjustable valve. | 4y
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This is a continuation of application Ser. No. 666,562 filed Mar. 15, 1976, U.S. Pat. No. 4,082,900.
BACKGROUND OF THE INVENTION
Titanium and titanium alloys find extensive use as the anti-corrosion material used in chemical plants or like apparatus. It is used in severely corrosive environment or of component parts of such apparatus. However, where non-oxidized solutions such as hydrochloric acid solutions are handled, active dissolution of titanium occurs. Also, where chloride solutions at high temperatures are handled, the problem of abnormal corrosion of inner intersticial parts of apparatus or crevice corrosion has not yet been solved.
Chemical apparatus has crevice in various parts, typical examples of which are flange points of liquid ducts at the gaskets. It will be readily understood that chemicals within the apparatus intrude into such crevice portions. Although the titanium material inhereintly has excellent corrosion resisting properties, its superficial portions cannot be perfectly immune to corrosion. When a reducing reaction proceeds in superficial portions and crevice portions within the apparatus, the concentration of the dissolved oxygen in such portions is reduced. While the superficial portions within the apparatus are replenished with dissolved oxygen from other portions (for instance central portion within the apparatus), replenishment of the dissolved oxygen in the crevices can hardly be expected. Consequently, oxygen concentration is reduced in effect only in the crevice portion, giving rise to the formation of a so-called oxygen concentration cell with the crevice portion acting as anode inducing an electrochemical reaction represented as
Ti + 2H.sub.2 O → TiO.sub.2 + 4H.sup.+ + 4e.sup.-
Thus, there results in an increase in hydrogen ion concentration and in the concentration of chloride ions in the crevice portion which cause the reaction as represented by
Ti → Ti.sup.+++ + 3e.sup.- ,
to occur, thus leading to abnormal corrosion of the crevice surface. In this case, although the majority of the inner surfaces of the apparatus are free from corrosion, leakage of process material from crevice portions, for instance pipe joints, is liable to result. This drastically lowers the safety of the entire chemical apparatus.
Known methods of preventing such corrosion include:
(1) using a titanium alloy containing 0.1 to 0.2 percent of palladium: and
(2) in which a platinum group element is deposited on the surface of the titanium material with or without subsequent diffusing treatment. However, the first method is economically disadvantageous because the π-Pd alloy uses a great quantity of expensive palladium, while the second method dictates complications of the manufacture of the apparatus, as well as calling for the consumption of a great quantity of the platinum group element.
The titanium material also has another drawback in that it tends to become embrittled hydrogen under high-temperature, high-pressure conditions. Under such circumstances the index of hydrogen absorption is high since generation of hydrogen due to corrosion reactions is highly possible, and this problem has recently become important. This tendency of the titanium material to become fragile due to hydrogen absorption is said to be attributable to the facts that hydrogen atoms immediately after generation in the cathode region are very apt to react with titanium and that the resultant hydride of titanium is very fragile. In order to prevent this absorption of hydrogen into titanium, it has been proposed to:
(1) deposite a metal which is potentially nobler than titanium, for instance platinum and palladium, on titanium: or
(2) subject the titanium material to anodizing or chemical oxidation treatment with chromic acid solution.
The former method is economically not practical for the same reasons as mentioned earlier, and also the range of its application is limited. In the second method, the oxide layer produced is reduced in a short period of time, so that it is impossible to expect a great effect of preventing hydrogen absorption.
SUMMARY OF THE INVENTION
The present invention seeks to solve the afore-mentioned problems. Its primary object is to provide a chemical apparatus, the crevice surfaces of which are provided with a corrosion preventive measure without substantial complicating its manufacture and which are economical advantageous.
A second object of the invention is to provide a chemical apparatus, with which sufficient prevention of crevice corrosion can be expected even under very severe conditions.
A third object of the invention is to provide a method of preventing crevice corrosion and hydrogen absorption in this type of chemical apparatus.
A first feature of the invention for achieving the above objects is to provide a mixed oxide layer of an oxide of a platinum group element and an oxide of an anti-corrosion metal on the surface of the titanium material of chemical apparatus at least over those areas constituting the interstitial portions. A second feature of the invention is to provide the said oxide layer over an area no less than 1/1,000, more preferably no less than 1/500, of the said titanium material surface. A third feature of the invention is to provide said oxide layer in a thickness no less than 0.01 micron, more preferably no less than 0.1 micron. A fourth feature of the invention is to set the molar ratio of the platinum group element oxide to the anti-corrosion metal oxide in the mixture within the range of from 1 : 99 to 95 : 5, more preferably from 10 : 90 to 95 : 5. A fifth feature of the invention is to provide said oxide layer through thermal treatment in an oxidizing atmosphere. A sixth feature of the invention is to carry out the thermal oxidation treatment of the fifth feature at a temperature ranging from 500° to 700° C. and for a period ranging from 10 to 30 minutes. A seventh feature of the invention is provide said layer on another oxide layer previously formed on the titanium material surface by heating the surface at 500° to 600° C. in atmosphere.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing relation of corrosion and hydrogen absorption of ion-treated Ti to the PdO content in mol % in PdO + TiO 2 mixture coating layer:
FIG. 2 is a graph showing corrosion in various sulfric acid concentrations;
FIG. 3 is a graph showing relation of corrosion and hydrogen absorption of non-treated Ti to the area ratio between treated Ti and non-treated Ti;
FIG. 4 is a graph showing relation of corrosion and hydrogen absorption of non-treated Ti to the thickness of coating layer; and
FIG. 5 shows a test piece for providing with crevice corrosion preventive treatment, in plan view in FIG. 5a and in section taken along line A--A in FIG. 5a in FIG. 5b.
DETAILED DESCRIPTION OF THE INVENTION
As the titanium material of the chemical apparatus according to the invention may be used such titanium alloys as Ti-5Ta, Ti-6Al-4V, Ti-5Al-2Cr-Fe, Ti5Al-2.5Sn, Ti-15Mo-5Zr, Ti-15Wo-5Zr-3Al as well as pure titanium, and it is of course possible to use combination of these alloys. While these titanium material constitute part or all of the inner surface of the chemical apparatus, part or all of the crevice surfaces must of course be constituted by the titanium material as is apparent from the purport of the instant invention.
Examples of the oxide of the platinum group element used according to the invention are those of iridium, platinum, ruthenium, rhodium, palladium and osmium, and from the standpoint of economy palladium oxide is most preferred. While examples of the oxide of the anti-corrosion metal are those of titanium, tantalum, zirconium, niobium, silicon and aluminum, it is possible to use any other oxide of an anti-corrosion metal as well.
The method of covering the chemical apparatus surface of the titanium material with a mixture of oxide composed of a platinum group element oxide and an anti-corrosion metal oxide is not limitative of the invention. The most effective method is to apply, for example, a solution containing a palladium salt and a titanium salt dissolved in a suitable solvent such as alcohol over the titanium material surface at least constituting the crevice portion. The coating is then subjected to a thermal oxidation treatment in an oxidizing atmosphere, for instance in atmosphere at 200 to 900° C. and for 10 to 30 minutes. It is further effective to form a preliminary titanium oxide layer on the Ti surface, which has previously been polished and washed with acid, by heating at 500 to 600° C. in the atmosphere prior to the step of coating with the aforementioned solution. Of course it is possible to coat with a mixture the oxides directly. While in this case an apparently uniform mixed oxide layer can be obtained, microscopically it has local pinholes which expose the base titanium material. Even in this case, however, the effect of preventing the corrosion of the crevice is not adversely affected by the local microscopic exposure of the titanium material. In the former case, that is, in the method based on oxidation treatment in the atmosphere, the mixed oxide layer is formed on the titanium material surface through chemical reactions. Thus, even if macroscopic defects result in this process, the titanium base in the defective portions is oxidized to form a stable oxide layer, for instance TiO 2 layer, so that very reliable suppression of the phenomenon of active dissolution (i.e., corrosion) of the titanium material itself can be advantageously achieved. Electronic spectrum analysis of the structure of the coating layers obtained by these methods reveals that there is some crystallographical coupling between the platinum group element oxide and the anti-corrosion metal oxide. More particularly, the platinum group element oxide is firmly bonded to the titanium material via the anti-corrosion metal oxide, thus providing not only electrochemical corrosion resistance and hydrogen absorption suppressing effect but also excellent mechanical properties such as wear resistance and shock resistance.
While oxides of platinum group elements have generally been known to have good corrosion resisting properties, they have been mainly noted for low threshold value of dissociation in electrolyte liquids (for instance chlorine over-voltage) compared to the pure metals. Their practical application, heretofore known, is as the electrolytic electrode (anode), where the property of anodic reactions is important and no problem is posed in connection with the corrosion of a titanium base. However, in the field of chemical apparatus using Ti-Pd alloys or palladium diffusion treated titanium, it was not been known as to whether or not such apparatus would exhibit sufficient corrosion resistance even under such corrosive conditions as where corrosion resistance is otherwise insufficient and also whether corrosion resistance of the titanium base can be ensured with the aforementioned mixed oxide layer. Neither was it totally known as to whether or not such layer has the effect of preventing hydrogen absorption.
The fact that according to the invention excellent corrosion resistance is achieved even under severe corrosive conditions such as those encountered with hydrochloric acid or sulfric acid is thought to result from the pronounced effect of forming a galvanic couple between the mixed oxide layer and the non-treated titanium surface portion. More particularly, the mixture of platinum group element oxide and the anti-corrosion metal oxide is thought to provide a very noble potential under the afore-mentioned corrosive conditions. Hence it has the excellent ability of rendering the galvanically coupled non-treated titanium material anodically polarized into a passive state.
The fact that the effect of preventing hydrogen absorption is improved according to the invention, is thought to be due to the very noble potential developed in the region of the mixed oxide layer coated titanium material in contact with the solution. In other words, while the platinum group element oxide in the mixed oxide layer has the main effect of producing hydrogen when cathode is formed, the speed of diffusion of hydrogen atoms into the anti-corrosion metal oxide in the coating is low enough to suppress the coupling of the hydrogen atoms to the base titanium material. In regions where the mixed oxide layer is not formed only the anodic reactions take place, so that these regions are apparently free from hydrogen absorption.
It is an important part of the invention to provide a mixed oxide layer composed of a platinum group element oxide and a corrosion resisting metal oxide on the surface of Ti material, whereby it is possible to obtain practically perfect prevention of crevice corrosion and tendency of becoming fragile due to hydrogen absorption even under severe conditions. The molar ratio of the platinum group element oxide to the anti-corrosion metal oxide in the mixture ranges from 1:99 to 95:5, more preferably from 10:90 to 95:5, as will be understood from an example given hereinunder.
Since the excellent effects can be obtained even with a small proportion of the platinum group element oxide, and also, since only a very small area of the material surface has to be covered with the coating, the economical value of the invention is very great. Where the proportion of the platinum group element oxide is less than 1 mol percent or greater than 95 mol percent, no considerable improvement can be obtained although it is possible to obtain some effect.
The coating layer according to the invention need not be provided over the entire area of the titanium material surface but may be provided only over no less than 1/1,000 of the total area, more preferably no less than 1/500 of the total area. While the thickness of the coating layer is not particularly limited, it is suitably not less than 0.01 micron in case where the improvement of the corrosion resistance is the primary aim and is suitably not less than 0.1 micron in case where the effect of preventing hydrogen absorption is primarily desired. The upper limit of the thickness is not critical, but 3 microns may be thought to be the upper limit because of economics. The thickness may be suitably adjusted by appropriately selecting, for instance, the method, number of times, density, etc., of coating solution containing the platinum group element salt and the corrosion resisting metal salt.
The following examples are given to illustrate the effects of the invention.
EXAMPLE 1
Pure titanium pieces 2 mm in thickness were subjected to sand blast treatment and then washed with hydrochloric acid, and then they were covered with respective PdO/TiO 2 mixture layers of compositions listed in Table 1. The resultant wafers were then individually coupled to pure titanium to prepare samples A. Also, there were prepared sample B by coupling PdO coated Ti to Ti, sample C by coupling Pd coated Ti to Ti, sample D by coupling Pd to Ti, sample E of the sole Ti-0.15% Pd alloy, and sample F of the sole Ti. Table 1 shows the results of measurements of the corrosion weight loss and hydrogen absorption of these samples, as measured after immersing them in boiling liquid containing 10 % sulfuric acid for 20 hours.
Table 1______________________________________ Hydrogen Corrosion weight absorp- loss tionSample structure (mg/15cm.sup.2 . 20hr) (ppm)______________________________________A Ti coupled with PdO/TiO.sub.2 4.1 6 (1/99) coated Ti Ti coupled with PdO/TiO.sub.2 4.1 0 to 3 (10/90) coated Ti Ti coupled with PdO/TiO.sub.2 4.0 0 to 3 (30/70) coated Ti Ti coupled with PdO/TiO.sub.2 4.0 0 to 3 (95/5) coated TiB Ti coupled with PdO coated 25.0 20 TiC Ti coupled with Pd coated Ti 27.0 28D Ti coupled with Pd 25.0 10E Ti-0.15 % Pd alloy (alone) 32.5 36F Ti (alone) 1120 640______________________________________ Note 1) In the coupled samples the area ratio of Ti to coupled material is 10 : 1 Note 2) The proportions of PdO and TiO.sub.2 in the samples A are in mol %. Note 3) Figures of the hydrogen absorption in the samples A, B and C represent th hydrogen absorption in non-coated Ti.
It will be seen from Table 1 that the corrosion weight loss and hydrogen absorption are least with the samples A according to the invention.
FIG. 1 shows results of tests conducted under the same conditions with samples coated with PdO-TiO 2 mixture layers with various proportions of PdO and TiO 2 , including the samples A in Table 1.
It will be understood from FIG. 1 that the molar ratio of PdO to TiO 2 in the mixture is suitably within a range from 1:99 to 95:5, more suitably within a range from 10:90 to 95:5.
EXAMPLE 2
Corrosion weight loss of pure Ti, Ti-0.15 % Pd alloy and 70 mol % PdO/30 mol % TiO 2 mixture coated Ti were measured after immersing the samples in various boiling liquids containing 5 to 10 % of sulfric acid for 20 hours, and FIG. 2 shows the results. As is seen from FIG. 2, in case of pure Ti corrosion increased sharply from the sulfric acid concentration of 0.5 %, and in case of Ti- 0.15 % Pd alloy corrosion began to increase sharply from a concentration of 2 % but with less corrosive weight reduction compared to the case of pure Ti. In contrast, the mixture layer coated titanium according to the invention showed excellent corrosion resisting property even at a sulfric acid concentration of 10 %. This steady corrosion resistance offered by the mixture layer coated titanium over a board sulfric acid concentration range is presumably owing to low hydrogen overvoltage in the coating layer compared to metallic palladium and also to excellent durability of the layer as the negative electrode.
EXAMPLE 3
Square pieces of titanium material, 25 mm long on each side (with a surface area of 13.5 cm 2 ) and 1 mm in thickness, were covered over the entire surface with a PdO/TiO 2 layer (with molar ratio of 70/30) and then coupled by galvanic coupling to non-treated Ti plates of different sizes to prepare samples of different area ratios. These samples were then immersed in boiling 10 % sulfric acid solution for 20 hours, and then the corrosion weight loss and hydrogen absorption of their non-treated Ti were measured to obtain results as shown in FIG. 3. It will be seen that the area ratio of the mixture oxide layer according to the invention to the titanium material may be no less than 1/1,000 for obtaining satisfactory effects of preventing corrosion and hydrogen absorption and no less than 1/500 for obtaining more satisfactory effects.
EXAMPLE 4
Square pieces of titanium material, 25 mm long on each side and 1 mm thick, were covered over the surface with PdO/TiO 2 layer (with molar ratio of 50/50) to various thicknesses and then individually coupled by galvanic coupling to pure Ti. These samples were then immersed in boiling 10 % sulfric acid solution for 20 hours, and then the corrosion weight loss and hydrogen absorption of their non-treated Ti were measured to obtain results as shown in FIG. 4. It will be seen that satisfactory results are obtainable when the thickness of the coating layer is greater than 0.01 micron, and particularly both corrosion and hydrogen absorption prevention effects are excellent with a thickness greater than 0.1 micron.
EXAMPLE 5
Mixture oxide coated titanium samples were prepared by using platinum group element oxides other than PdO and corrosion resisting metal oxides other than TiO 2 , and their anti-corrosion and hydrogen absorption preventive property were measured under the same conditions as in Example 2 to obtain results as shown in Table 2. (The molar ratio between the platinum group element oxide and corrosion resisting metal oxide was set to 1:1, and the area ratio between coated portion and non-coated portion was also set to 1:1.)
Table 2______________________________________ Hydrogen Corrosion weight loss absorptionSample (mg/15cm.sup.2. (ppm)______________________________________PtO/TiO.sub.2 4.1 0 - 3RuO.sub.2 /TiO.sub.2 4.2 0 - 3IrO.sub.2 /TiO.sub.2 4.5 0 - 3RhO.sub.2 /TiO.sub.2 4.0 0 - 3O.sub.3 O.sub.2 /TiO.sub.2 6.4 0 - 5PdO/Ta.sub.2 O.sub.5 4.0 0 - 3PdO/ZrO.sub.2 4.1 0 - 3PdO/Nb.sub.2 O.sub.5 4.1 0 - 3Contrast PdO/TiO.sub.2 4.0 0 - 3______________________________________
It will be seen from Table 2 that both corrosion resistance and hydrogen absorption resistance were pronounced in all samples except for the sample of OsO 2 /TiO 2 , in which slightly high values resulted.
EXAMPLE 6
Pure titanium pieces 2 mm in thickness were washed in the manner as described in Example 1 and then covered with a PdO/TiO mixture layer (with the molar ratio of the components of the layer per to 1:1, the thickness of the layer to 1 micron and the area ratio between coated portion and non-coated portion to 1:1) under various heating conditions. The layer of mixture oxide was formed by applying a methanol solution containing palladium chloride and titanium chloride dissolved therein over the surface of the piece. Table 3 shows results of measurements of the corrosion weight loss and hydrogen absorption of the samples, the measurement being conducted in the manner as described in Example 1.
Table 3______________________________________ HydrogenConditions for thermal Corrosion weight loss absorptionoxidation (mg/15 cm.sup.2.20 h) (ppm)______________________________________1) 300° C. 10 minutes 28.4 232) 500° C. 10 minutes 4.0 0 to 33) 500° C. 30 minutes 2.2 0 to 34) 700° C. 10 minutes 2.5 0 to 35) 900° C. 10 minutes 19.3 17______________________________________Contrast Actively Non-coated Ti dissolved 640 Ti-Pd alloy 32.5 36______________________________________
As is seen from Table 3, the most excellent corrosion resistance and hydrogen absorption resistance were obtained when the thermal oxidation was carried out under conditions of 500 to 700° C. and 10 to 30 minutes. At heating temperatures below 300° C. the percentage of conversion of Pd into PdO was reduced to result in slightly interior corrosion resistance. Also, the corrosion resistance was slightly reduced with temperature conditions above 900° C.
EXAMPLE 7
Square pieces of titanium material, 25mm long on each side and 1mm in thickness, were covered over the entire surface with a mixture oxide layer which is shown in table 4 and then coupled by galvanic coupling to non-treated Ti plates of the same size.
These samples were immersed in boiling 10% sulfuric acid solution for 20 hours, and then the corrosion weight loss and hydrogen absorption of their non-treated Ti were measured to obtain results as shown in table 4.
TABLE 4______________________________________ HYDROGEN AB- CORROSION WEIGHT LOSS SORPTIONSAMPLE (mg/15m.sup.2 /20 hours) (PPM)______________________________________PdO 30/PtO 20/TiO.sub.2 50 4.3 0-3PdO 30/RuO.sub.2 20/TiO.sub.2 50 4.2 0-4PdO 70/RuO.sub.2 10/TiO.sub.2 20 4.3 0-3PtO 40/IrO.sub.2 20/Ta.sub.2 O.sub.5 40 4.3 0-5RhO.sub.2 30/RuO.sub.2 10/ZrO.sub.2 60 4.1 0-4RhO.sub.2 70/IrO.sub.2 10/TiO.sub.2 20 4.3 0-3PdO 40/RuO.sub.2 20/IrO.sub.2 10/TiO.sub.2 30 4.2 0-3PdO 40/TiO.sub.2 20/Ta.sub.2 O.sub.5 40 4.3 0-3PdO 70/TiO.sub.2 30 4.0 0-3______________________________________
It will be seen from table 4 that the prevention of corrosion and hydrogen absorption can be effectively achieved by covering the Ti plate with the mixture oxide composed at least two platinum group elements and a anti-corrosion metal or at least two anti corrosion metals and platinum group element.
EXAMPLE 8
Crevice corrosion test pieces were prepared by forming PdO/TiO 2 mixture layers (3 microns thick) of various PdO contents on respective inch square piece assemblies consisting of two overlapping thin titanium plates having a central aperture as shown in FIG. 5. In the Figure, designated at 1 is the thin titanium plates, at 2 Teflon insulators, at 3 a titanium bolt, and at 4 a titanium nut. The PdO/TiO 2 mixture layer was formed by applying a solution containing palladium chloride and titanium chloride dissolved therein over the surface of each assembly, followed by thermal oxidation in an atmosphere at 550° C. for 10 minutes.
The crevice corrosion of the samples prepared in this way was then observed after immersing them in a boiling aqueous solution containing 44 % of ammonium chloride for 240 hours, and Table 5 shows the results. A non-coated piece assembly was also tested as contrast in the same manner.
Table 5______________________________________ Test Con-specimen trast Coated specimens______________________________________PdO (mol %)in coatinglayer -- 0.5 1 30 70 95 97crevice Pre-corrosion sent Slight Non Non Non Non Slight______________________________________
As is seen from Table 5, the crevice corrosion was reduced by the provision of the mixture coating layer, and particularly it was suppressed substantially perfectly when the PdO content was 1 to 95 mol %.
As has been described in the foregoing, according to the invention it is possible to achieve reliable prevention of crevice corrosion and hydrogen absorption in a very economical method and also steadily ensure this even under considerably severe corrosive conditions, which is very beneficial in industry in view of the safety and extension of life of chemical apparatus. | 4y
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser. No. 13/644,936, filed on Oct. 4, 2012, the disclosure of which is incorporated herein by reference in its entirety.
FIELD
[0002] The inventive subject matter relates to power conversion apparatus and methods and, more particularly, to uninterruptible power supply (UPS) apparatus and methods.
BACKGROUND
[0003] UPS systems are commonly used in installations such as data centers, medical centers and industrial facilities to provide backup power to maintain operation in event of failure of the primary utility supply. These UPS systems often have an “on-line” configuration including a rectifier and inverter coupled by a DC link that is also coupled to an auxiliary power source, such as a battery, fuel cell or other energy storage device. Other configurations, such as standby and line-interactive configurations, may also be used. UPS systems may have a modular structure including two or more UPS modules, each of which may include, for example, a rectifier, an inverter and a DC/DC converter for interfacing to a battery or other DC power source. The modules commonly are designed to operate in parallel to provide scalable power capacity, e.g., the modules may be coupled in common to an AC source, a DC source (e.g., a battery) and/or a load.
[0004] Power supply systems using UPSs, such as those used for data center applications, may be configured in a variety of different redundant configurations to increase reliability and availability. Various redundant UPS arrangements are described, for example, in U.S. Pat. No. 7,265,458 to Edelen et al.
[0005] As shown in FIG. 1 , UPSs may be used in what is referred to an “A-B” configuration. A UPS 110 may have a first AC input 101 coupled to a power conversion chain including a rectifier 112 and an inverter 114 and a second AC input 102 coupled to a semiconductor static switch 116 that acts as a bypass. The UPS 110 may also include a DC/DC converter 118 coupled to a DC link between the rectifier 112 and the inverter 114 and configured to be coupled to a battery 10 .
[0006] Both of the AC inputs 101 , 102 of the UPS 110 may be coupled to a first source A. An AC output 103 of the UPS 110 may be coupled to a first static switch 122 of a separate dual switch assembly 120 . A second static switch 124 of the dual switch assembly 120 may be coupled to a second AC source B, which may be another UPS. An output of the dual switch assembly 120 is coupled to a critical load 130 . If the source A fails, the UPS 110 may provide power from its battery. If the UPS 110 fails, the load 130 may be served from the second source B via the second static switch 124 of the dual switch assembly 120 .
SUMMARY
[0007] Some embodiments of the inventive subject matter provide an uninterruptible power supply (UPS) including a frame, at least one AC input supported by the frame and configured to be coupled to at least one external power source and at least one AC output supported by the frame and configured to be coupled to at least one external load. The UPS also includes a power conversion circuit supported by the frame and having an output coupled to the at least one AC output, the power conversion circuit configured to selectively provide power from first and second power sources. The UPS further includes first and second static switches supported by the frame and configured to couple and decouple the at least one AC input to and from the at least one AC output and a control circuit supported by the frame and configured to cooperatively control the power conversion circuit and the first and second static switches.
[0008] The power conversion circuit may include a rectifier having an input coupled to the at least one AC input, a DC link coupled to an output of the rectifier and an inverter having an input coupled to the DC link and an output coupled to the at least one AC output. In some embodiments, the control circuit may be configured to concurrently close the first static switch and open the second static switch to support an increased efficiency mode of operation. The frame may include an enclosure containing the power conversion circuit and the first and second static switches.
[0009] Some embodiments provide a system including a plurality of UPSs, each including a frame, at least one AC input supported by the frame and configured to be coupled to at least one external power source, at least one AC output supported by the frame and configured to be coupled to at least one external load, a power conversion circuit supported by the frame and having an output coupled to the at least one AC output, first and second static switches supported by the frame and configured to couple and decouple the at least one AC input to and from the at least one AC output and a control circuit supported by the frame and configured to cooperatively control the power conversion circuit and the first and second static switches. The system further includes first and second AC power sources coupled to respective ones of the first and second static switches of the plurality of UPSs. The plurality of UPSs may include a plurality of first UPSs and the second AC power source may include at least one second UPS. Respective ones of the plurality of UPSs may be coupled to respective loads.
[0010] Further embodiments provide a system including a UPS that includes a frame, at least one AC input supported by the frame and configured to be coupled to at least one external power source, at least one AC output supported by the frame and configured to be coupled to at least one external load, a power conversion circuit supported by the frame and having an output coupled to the at least one AC output, first and second static switches supported by the frame and configured to couple and decouple the at least one AC input to and from the at least one AC output and a control circuit supported by the frame and configured to cooperatively control the power conversion circuit and the first and second static switches. The system further includes first and second loads coupled to respective ones of the first and second static switches.
[0011] In some embodiments, the first static switch may be coupled between an AC power source and the first load and the second static switch may be coupled between the first static switch and the second load. In further embodiments, the first static switch may be coupled between an AC power source and the first load and the second static switch may be coupled between the AC power source and the second load.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic diagram illustrating a conventional power distribution system configuration.
[0013] FIG. 2 is a schematic diagram illustrating an uninterruptible power supply (UPS) according to some embodiments of the inventive subject matter.
[0014] FIGS. 3-7 are schematic diagrams illustrating power distribution systems according to various embodiments of the inventive subject matter.
[0015] FIG. 8 is an elevation showing a physical configuration of a UPS according to some embodiments.
DETAILED DESCRIPTION
[0016] Specific exemplary embodiments of the inventive subject matter now will be described with reference to the accompanying drawings. This inventive subject matter may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the inventive subject matter to those skilled in the art. In the drawings, like numbers refer to like elements. It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. As used herein the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0017] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the inventive subject matter. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes,” “comprises,” “including” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0018] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this inventive subject matter belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0019] FIG. 2 illustrates a UPS 200 according to some embodiments of the inventive subject matter. The UPS 200 includes a frame 210 . The frame 210 supports at least one AC input 201 for connection to at least one external AC power source and at least one AC output 202 for connection to at least one external load. Such connections may be provided using, for example, plug-in type connectors, terminal strips, wire lugs or the like. The UPS 200 also includes a power conversion circuit including a rectifier 211 and an inverter 212 , also supported by the frame 210 . The UPS 200 further includes a DC/DC converter 213 , first static switch 215 , second static switch 216 and associated control circuit 217 supported by the frame 210 .
[0020] The rectifier 211 is coupled to the at least one AC input 201 , and is configured to produce a DC voltage on a DC link 214 from AC power provided at the at least one AC input 201 . The inverter 212 is coupled to the DC link 214 and to the at least one AC output 202 and is configured to generate an AC voltage at the at least one AC output 202 from a DC voltage on the DC link 214 . The DC/DC converter 213 is also coupled to the DC link 214 and is configured to interface to a battery 10 , here shown as located external to the UPS 200 . In some embodiments, the DC/DC converter 213 may be omitted, and a direct connection between the battery 10 and the DC link 214 may be provided. In some embodiments, the battery 10 may be included in the UPS 200 , i.e., may be supported by the common frame.
[0021] The first static switch 215 is coupled to the at least one AC input 201 and to the at least one AC output 202 and provides a switchable path therebetween under control of the control circuit 217 . Similarly, the second static switch 216 is coupled to the at least one AC input 201 and to the at least one AC output 202 and provides a switchable path therebetween under control of the control circuit 217 . As shown, the first and second static switches 215 , 216 may be implemented using anti-parallel connected thyristors (e.g., silicon-controlled rectifiers (SCRs)), but it will be understood that the first and second static switches 215 , 216 may be implemented using other arrangements of semiconductor and/or mechanical switching devices. Although the UPS 200 of FIG. 2 may provide respective external connections for the rectifier 211 , inverter 212 and the first and second static switches 215 , 216 it will be appreciated that common external connections may be provided for subsets of these components. For example, the rectifier 211 and the first static switch 215 may be internally connected such that a single external connection may be used for both the rectifier 211 and the first static switch 215 . Similarly, the inverter 212 and the first static switch 215 may be internally connected such that a single external connection may be used for both the inverter 212 and the first static switch 215 .
[0022] A control circuit 217 is configured to control the rectifier 211 , inverter 212 , DC/DC converter 213 and the first and second static switches 215 , 216 in a coordinated manner. For example, in the event of a failure of the rectifier 211 , the inverter 212 or an AC power source coupled to the rectifier 211 , the control circuit 217 may operate one of the first and second static switches 215 , 216 to provide an alternate path for power flow to the load 20 . The control circuit 217 may also operate one of the first and second static switches 215 , 216 to support an increased efficiency mode of operation in which the rectifier 211 and the inverter 212 are bypassed to provide power directly to the load 20 , with the inverter 212 operating in a standby or active filter mode to provide battery backup power and/or power conditioning. It will be understood that, in general, the control circuit 217 may be implemented using analog circuitry, digital circuitry or combinations thereof. The control circuit 217 may include, for example, one or more data processing devices, such as a microprocessor or microcontroller, along with circuitry for driving power conversion components of the rectifier 211 and inverter 212 and the first and second static switches 215 , 216 .
[0023] As described herein, a UPS, such as the UPS 200 of FIG. 2 , is a unitary, discrete assembly configured as a single unit, as opposed to a collection of physically separated units interconnected by wiring external to the units (e.g., cables run loosely or in conduits or cable trays). In FIG. 2 , the UPS 200 is shown as including a frame 210 conceptually illustrated using a bounding rectangle. In some embodiments, the frame 210 may be a supporting structure, such as an enclosure or housing or a set of housings conjoined or otherwise attached in a manner that provides a unitary structure. The enclosure or housing may be open, closed or may have open and closed portions and/or portions that may be accessible via doors or similar features. The enclosure or housing may contain components, such as support struts, support rails, interior shelves, etc., that are used to support electrical components of the UPS, such as the rectifier 211 , inverter 212 , DC/DC converter 212 and other electrical components of the UPS 200 of FIG. 2 . An example of such a frame is illustrated in FIG. 8 , which shows a UPS 800 with a unitary frame 810 including multiple cabinet-like sections 812 a , 812 b , 814 , 816 a , 816 b , 816 c conjoined to form a structural unit. The UPS 800 is provided for purposes of illustration, and it will be appreciated that other frame arrangements may be used in some embodiments.
[0024] FIG. 3 illustrates an exemplary use of the UPS 200 of FIG. 2 to provide source redundancy according to some embodiments. First and second UPSs 200 a , 200 b have their rectifiers 211 coupled to a first AC power source A and their inverters 212 coupled to respective loads 20 a , 20 b . The first static switches 215 of the first UPS 200 a and the second UPS 200 b are also coupled to the first AC power source A, while the second static switches 216 of the first UPS 200 a and the second UPS 200 b are coupled to a second power source B. It will be appreciated that coupling between the first static switches 215 and the rectifiers 211 and inverters 212 may be external and/or may be internal to the UPSs 200 a , 200 b , as discussed above with reference to FIG. 2 .
[0025] Some UPSs having a static bypass may be operated to provide a high efficiency mode wherein the bypass path is closed, allowing power to be transferred directly from the UPS input to the UPS output without passing through a rectifier/inverter chain, thus reducing losses associated with the operation of those components. Such a mode may be used, for example, when the AC input meets power quality criteria, with the rectifier/inverter chain being placed in a standby and/or active filter state. In such a state, the rectifier/inverter chain may be re-engaged should the AC input cease to meet those power quality criteria. Examples of such high-efficiency operating modes are described, for example, in U.S. Pat. No. 6,295,215 to Faria et al.
[0026] An arrangement along the lines shown in FIG. 3 may be particularly advantageous for providing redundant sourcing while also supporting a high efficiency mode. Referring to FIG. 3 , when operating the first UPS 200 a or the second UPS 200 b in an on-line mode, the first and second static switches 215 , 216 are open. If it is desired to transfer to a high-efficiency bypass mode, the control circuit 217 may close the first static switch 215 , thus bypassing the rectifier 211 and inverter 212 . In this mode, the inverter 212 may operate in a standby and/or active filtering mode, along the lines discussed above. The second static switch 216 provides the capability for the control circuit 217 to transition from the high-efficiency mode to the alternative second AC source B in the event the first AC source A fails. Because control of the first and second static switches 215 , 216 is integrated with control of the rectifier 211 and the inverter 212 in a single UPS, this operation may be performed more smoothly and/or reliably, as coordination with external switches or other downstream devices may not be required.
[0027] UPSs according to some embodiments may also be used advantageously in isolated redundant and other power system arrangements. For example, as shown in FIG. 4 , a power system may include first, second and third UPSs 200 a , 200 b , 200 c , each including a rectifier 211 , inverter 212 , DC/DC converter 213 and first and second static switches 215 , 216 . The rectifiers 211 and first static switches 215 of the UPSs 200 a , 200 b , 200 c are coupled to a first power source A. The second static switches 216 of the UPSs 200 a , 200 b , 200 c are coupled to the output of a fourth UPS 300 . A rectifier 311 of the fourth UPS 300 is configured to be coupled to the first power source A such that, in the event of the failure of the rectifier 211 and/or inverter 212 or one or more of the first, second and third UPSs 200 a , 200 b , 200 c , power may be passed via the rectifier 311 and inverter 312 of the fourth UPS 300 and the second static switch 216 of the affected one or more of the first, second and third UPSs 200 a , 200 b , 200 c . If the first power source A fails when in this configuration, power may be supplied from the battery associated with the fourth UPS 300 via the inverter 312 of the fourth UPS 300 and the second static switch 216 of the affected one or more of the first, second and third UPSs 200 a , 200 b , 200 c . Should the rectifier 311 and/or inverter 312 of the fourth UPS 300 fail, a static switch 315 of the fourth UPS 300 may be closed, allowing power to pass from an alternative power source B to the second static switches 216 of the first, second and third UPSs 200 a , 200 b , 200 c.
[0028] It will be appreciated that UPSs according to some embodiments of the inventive subject matter may be advantageously used in other power system arrangements, for example, to enable provision of power to separate loads from a single UPS. FIG. 5 illustrates an application in which a first UPS 200 as discussed above with reference to FIG. 2 is coupled to a first power source A and to a first load 20 a . A second UPS 500 , which includes a rectifier 511 and an inverter 512 and a DC/DC battery converter 513 coupled to a DC link 514 , is coupled to a second power source B and a second load 20 b . A static switch 515 is configured to bypass the rectifier 511 and the inverter 512 . The second power source B is coupled to the rectifier 511 and the static switch 515 , and the second load 20 b is coupled to the inverter 512 and the static switch 515 .
[0029] The rectifier 211 of the first UPS 200 is coupled to the first power source A, while the inverter 212 is coupled to the first load 20 a . A first static switch 215 of the first UPS 200 is coupled connected to the first power source A and to the first load 20 a and a second static switch 216 of the first UPS 200 . The second static switch 216 of the first UPS 200 is also coupled to the second load 20 b . This arrangement allows the first UPS 200 to provide power to the second load 20 b from the inverter 212 or from the first power source A via the second static switch 216 . The second static switch 216 may also be used to provide power to the first load 20 a from the second UPS 500 , i.e., from either the inverter 512 or via the static switch 515 .
[0030] FIG. 6 illustrates a further application of a UPS 200 along the lines discussed above with reference to FIG. 2 . A rectifier 211 is coupled to a power source A, while an inverter 212 is coupled to a first load 20 a . A first static switch 215 is connected between the power source A and the first load 20 a , while the second static switch 216 is coupled between the power source A and a second load 20 b . The first load 20 a may be, for example, a critical load for which UPS redundancy is desirable, while the second load 20 b may be, for example, non-critical load that does not require UPS protection.
[0031] FIG. 7 illustrates yet another application of a UPS 200 along the lines discussed above with reference to FIG. 2 . A rectifier 211 is coupled to a power source A, which an inverter 212 is coupled to a first load 20 a . A first static switch 215 is coupled between the power source A and the first load 20 a . A second static switch 216 is coupled between inverter 212 and first static switch 215 and a second load 20 b . This arrangement may allow for shedding of the second load 20 b under certain circumstances, for example, when the UPS 200 is operating in an on-line and/or on-battery mode and has insufficient capacity to power both the first load 20 a and the second load 20 b.
[0032] It will be appreciated that the power system arrangements of FIGS. 3-7 are provided for purposes of illustrations, and that UPSs according to further embodiments may be used in other ways.
[0033] In the drawings and specification, there have been disclosed exemplary embodiments of the inventive subject matter. Although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the inventive subject matter being defined by the following claims. | 4y
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TRADEMARKS
[0001] IBM® is a registered trademark of International Business Machines Corporation, Armonk, N.Y., U.S.A. Other names used herein may be registered trademarks, trademarks or product names of International Business Machines Corporation or other companies.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to dynamically extending XML-based remote service by clients and particularly to extending Service Data Objects (SDO)-based remote service from client.
[0004] 2. Description of Background
[0005] XML-based service use Extensible Markup Language (XML) to describe the data passed in and out from the interface. The structure of the XML is defined by XML Schema Definition (XSD). For example, SDO-based services use service data objects as their input and output parameters. The structure of the data service object is defined by XSD.
[0006] SDO is a data programming specification that complements existing Java 2 Enterprise Edition (J2EE) technologies and enables service-oriented architectures by providing uniform data access for a wide variety of service and resource types. Not only does SDO enable a consistent approach to data access, but it also provides features that simplify common application tasks, such as allowing data browsing and updating while the application is disconnected from the data source. SDOs are designed to simplify and unify the way applications handle data. By using SDOs, application programmers can uniformly access and manipulate data from heterogeneous data sources, including relational databases, XML data sources, Web services, and other such enterprise information systems. Since SDO provides a single data access API (Application Program Interface), developers can choose the framework that best fits an application without learning to use different APIs for every application.
[0007] Eclipse Modeling Framework (EMF) is based on a data model defined using Java interfaces, XML Schema, or UML class diagrams, EMF will generate a unifying meta model (called Ecore) which in conjunction with the framework can be used to create a high-quality implementation of the model. IBM's reference implantation of SDO is based on EMF. In this implementation, the XSD needs to load into memory and registered in the Java Virtual Machine (JVM) as Ecore model before the SDO can be created. Ecore model is represented in Java as schema packages (org.eclipse.emf.ecore.EPackage).
[0008] The behavior and capability of XML-based service can be extended by extending the interface schema. There are applications which require the schema to be extended by clients dynamically. “Remote” means the client and the service are running in different JVMs. “Dynamically” means the service does not need to restart to support the extension. For SDO-based remote service, this means once the schema (Ecore model) is extended, it needs to re-register the schema on both client and server side.
[0009] There a several challenges to achieve this. First, the Ecore model needs to be transferred from server to clients. But Ecore model (schema packages) is not serializable. In other words, the schema packages cannot be directly transferred between two JVMs remotely. A second challenge is that every client has to retrieve the schema packages and register the schema packages before calling the server and needs to do this every time the schema packages on server change. This increases the complexity of the client application, making SDO-based remote service difficult to use.
[0010] Considering the limitations of the aforementioned methods, it is clear that there is a need for an efficient method for clients to extend SDO-based remote service dynamically.
SUMMARY OF THE INVENTION
[0011] The difficulties are overcome and additional advantages are provided through the provision of a system for dynamically extending remote service interface by clients. The system comprising: a SDO-based local service and the client; a SDO-based remote service and the server where the remote service is running. The local service provides the functions for locating remote service, retrieving schema packages and register schema. The remote service provides the function for getting schema, allowing extending schema and support extended schema dynamically.
[0012] The difficulties are overcome and additional advantages are provided through the provision of a method for dynamically extending SDO-based remote service by client though SDO-based local service. The method comprising the following. Create a SDO-based local service in client's JVM. It has the same interface as the remote service interface. Client calls this local service instead of remote service. Local service locates remote service and sends request for retrieving Ecore model. The remote service will convert the Ecore model from schema packages to a serializable format and send back to local service. Local service restores the serializable format to schema packages and register in the client's JVM.
[0013] Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and the drawings.
TECHNICAL EFFECTS
[0014] As a result of the summarized invention, technically we have achieved a solution that provides for an efficient method for dynamically extending SDO-based remote service through clients.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0016] FIG. 1 illustrates one example of a block diagram describing the initialization process for a SDO-based remote service and local service when a client calls the local service for the first time;
[0017] FIG. 2 illustrates one example of a block diagram describing how the client extends the SDO-based remote service through the local service and use the extended service.
DETAILED DESCRIPTION OF THE INVENTION
[0018] One aspect of the exemplary embodiments is a method for client to retrieve schema from SDO-based remote service. In another aspect of the exemplary embodiments, a remote service interface is dynamically changed at runtime, by a client, by extending the schema of the data object to include more attributes. In yet another exemplary embodiment, the remote service's business logic is able to interpret new schema and support the new attributes without restart the server.
[0019] SDO-based local service is a proxy of the SDO-based remote service at the local JVM (Java Virtual Machine) of clients. The SDO-based local service implements the SDO-based remote service so that client applications can use it the same way as the SDO-based remote service. The implementation of the local service solves the problem of transferring schema remotely by converting them to serializable form of byte arrays. In addition, the implementation hides the complexity of looking up remote service, and retrieving and registering schema from the clients. As a result, by using an SDO-based local service, the exemplary embodiments of the present invention allow clients to dynamically extend the interface of remote service remotely at runtime. The schema used may be extended to support additional syntaxes, matching rules, attribute types, and object classes. For example, following is a sample method of SDO-based EJB service, which allows a client to create a “Person.” For instance:
[0000]
create(Person person)
“Person” is a service data object. The attributes of the “Person” type is
defined in XML schema. According to the schema, “Person” type contains
only “givenName” and “FamilyName” two attributes:
<xsd:complexType name=“Person”>
<xsd:complexContent>
<xsd:element name=“givenName” type=“xsd:string”/>
<xsd:element name=“familyName” type=“xsd:string”/>
</xsd:complexContent>
</xsd:complexType>
[0020] Assume a client wishes to create a new type called “Employee,” which extends from “Person” type with one additional attribute called “EmployeeNumber.” The client may also desire to perform this operation dynamically at runtime, which means the service cannot be stopped and restarted. The new XML schema will look like this:
[0000]
<xsd:complexType name=“Employee”>
<xsd:complexContent>
<xsd:extension base=“Person”>
<xsd:sequence>
<xsd:element name=“EmployNumber” type=“xsd:string
</xsd:complexContent>
</xsd:complexType>
[0021] For the SDO-based remote service, which allows clients to dynamically extend its interface, two support methods may be desired. These support methods are: (1) “getSchema”, which allows clients to retrieve latest schema from service, and (2) “addSchema”, which allows clients to extend service interface by adding new schema. Besides these two methods, a method “create” is provided to allow client to create a new “Person” or “Employee”.
[0022] Referring to FIG. 1 , one example of a block diagram describing an initialization process 10 for a SDO-based remote service and local service is illustrated. The initialization process 10 includes the following system components: a client JVM 12 in communication with a server JVM 14 . The client JVM 12 includes Ecore model 16 , client 118 and SDO-based local service 34 . The server JVM 14 includes Ecore model 22 and SDO-based remote service 30 . The method “getSchema” 24 , the method “addSchema” 26 , and the method “create” 28 are included in a SDO-based remote service 30 . XSD Schema Files 20 is located on server. The SDO-based local service 34 is in communication with SDO-based remote service 30 via communication link 32 , which includes locate, retrieves/return and create.
[0023] The communication of the SDO-based local service 34 with the SDO-based remote service 30 can be summarized as follows. (1) During the start process of SDO-based remote service 30 , it loads the schema from XSD schema files 20 and registers the schema as Ecore model 22 in the Server JVM 14 . (2) Client 118 calls SDO-based local service 34 to create a “Person”. (3) Since this is the first time SDO-based local service 34 being called, it needs to locate the SDO-based remote service 30 . (4) After the service is located, SDO-based local service 34 calls method “getSchema” 24 to request the schema from the SDO-based remote service 30 . (5) The service serializes the Ecore model 22 in server JVM 14 to byte array. (6) The serialized schema is then returned back to the SDO-based local service 34 . (7) After receiving the byte array form of the schema, the SDO-based local service 34 restores it back to Ecore model 16 and register it in client JVM 12 . (8) Finally, the SDO-based local service 34 continue the call from the client 118 by calling method “create” 28 of SDO-based remote service 30 . This method will create new “Person” on the server.
[0024] Referring to FIG. 2 , one example of a block diagram describing an extension process 40 for a client to dynamically extend the SDO-based remote service interface though the help of the SDO-based local service is illustrated. The extension process 40 includes the following system components: a client JVM 42 in communication with a server JVM 44 . The client JVM 42 includes Ecore model 46 , client 148 and SDO-based local service 64 . The server JVM 44 includes Ecore model 54 and SDO-based remote service 62 . The method “getSchema” 56 , the method “addSchema” 58 , and the method “create” 60 are included in a SDO-based remote service 62 . XSD Schema Files 52 is located on server. The SDO-based local service 64 is in communication with SDO-based remote service 62 via retrieves/return, addSchema and create with communication link 50 .
[0025] Specifically, the communication of the SDO-based local service 64 with the SDO-based remote service 62 can be summarized as follows. (1) The client calls the method “addSchema” of SDO-based local service 64 to add a new type called “Employee,” which has a new attribute called “EmployeeNumber.” (2) SDO-based local service 64 passes the call to SDO-based remote service 62 . (3) SDO-based remote service 62 validates the new schema to make sure that the request does not change the existing schema, only add new schema to existing schema. After validation, SDO-based remote service 62 merges the added schema with existing schema and registers the new schema as Ecore model 54 in the Server JVM 44 . (4) The SDO-based remote service 62 saves the schema back to schema files so that the new schema is still there when service restarts. The server business logic should be able to interpret the new schema and change its internal configuration to support this new type “Employee”. (5) SDO-based local service 64 calls method “getSchema” 56 to request the new schema from the SDO-based remote service 62 . (6) The service serializes the Ecore model 54 in server JVM 44 to byte array. (7) The serialized schema is then returned back to the SDO-based local service 64 . (8) After receiving the byte array form of the schema, the SDO-based local service 64 restores it back to Ecore model 46 and register it in client JVM 42 . (9) The client 148 can now call the method “create” to create the new type “Employee” with new attribute “EmployeeNumber.” (10) SDO-based local service 64 passes the call to SDO-based remote service 62 to finish the call to create the new type “Employee”.
[0026] In the implementation of the algorithm, the SDO-based local service help clients to do the entire schema related tasks. This can relieve clients from the above work and concentrate on business functions, thus effectively using resources.
[0027] Since the new schema extends, not changes the existing schema, the new schema should not affect other clients. If another client attempts to extend the service interface with new schema that conflicts with the new schema created by a first client (e.g., creating a new type which also named “Employee” in the same name space), then the service makes an exception to this request. Specifically, the client calls method “getSchema” to retrieve the latest schema from service and use the “Employee” type created by the first schema. The client can also try to create the type again with different name or different name space.
[0028] Following are some sample code of the implementation for the process in FIG. 1 and FIG. 2 :
[0029] When a client needs to access SDO-based remote service, it creates an SDO-based local service instance first. In the following example, the remote server is implemented as EJB interface. “LocalServiceProvider” is the SDO-based local service. An instance of “LocalServiceProvider” is created with the host name of the remote EJB server and the RMI (Remote Method Invocation) port. Specifically:
[0000]
// Client application creates a SDO-based local service instance.
com.ibm.websphere.wim.Service service = new
LocalServiceProvider(“localhost”, 2809);
[0030] During the initialization of the SDO-based local service instance, it looks up the remote service, and then retrieves the schema packages from the service. For example, the getSchema method of the remote service converts the Ecore model from “EPackage” to byte arrays. The following exemplary code illustrates a method of performing such task:
[0000]
// Creates ResourceSet
org.eclipse.emf.ecore.resource.Resource.Factory.Registry.INSTANCE.-
getExtensionTo
FactoryMap( ).put(“ecore”, new EcoreResourceFactoryImpl( ));
org.eclipse.emf.ecore.resource.ResourceSet rs = new
org.eclipse.emf.ecore.resource.impl.ResourceSetImpl( );
org.eclipse.emf.ecore.resource.Resource r =
rs.createResource(URI.createURI(“.ecore”));
// Adds all related EPakcages
org.eclipse.emf.ecore.EPackage ePackage
=EPackage.Registry.INSTANCE.getEPackage(nsURI);
r.getContents( ).add(ePackage);
// Converts to bypte array
java.io.ByteArrayOutputStream outputstream = new
java.ioByteArrayOutputStream(2064);
r.save(outputstream, Collections.EMPTY_MAP);
return outputstream.toByteArray( );
[0031] After the SDO-based local service instance obtains the byte arrays from SDO-based remote service, it restores the schema packages from byte arrays back to “EPackage”, and registers them in a local VJM as Ecore model:
[0000]
// Retrieves byte array form of schema packages from remote service
bypte[ ] schemabytes = service.getSchema(null);
// Converts byte array to EPackage
Resource.Factory.Registry.INSTANCE.getExtensionToFactoryMap( ).-
put(“ecore”,
new EcoreResourceFactoryImpl( ));
ByteArrayInputStream is = new ByteArrayInputStream(schemabytes);
ResourceSet rs = new ResourceSetImpl( );
Resource cr = rs.createResource(URI.createURI(“.ecore”));
cr.load(is, Collections.EMPTY_MAP);
// Registers EPackage in local JVM.
List packages = cr.getContents( );
for (int i = 0; i < packages.size( ); i++)
{
EPackage thisPackage = (EPackage)cr.getContents( ).get(i);
String packageURI = thisPackage.getNsURI( );
thisPackage.setEFactoryInstance(new
DynamicEDataObjectImpl.FactoryImpl( ));
EPackage.Registry.INSTANCE.put(packageURI, thisPackage);
}
[0032] All the above steps are transparent to the client. They are part of the initialization process of the SDO-based local service. After the client creates this new instance of SDO-based local service, the client can then access the remote service through this local service. For example:
[0000]
// Client application creates a SDO-based local service instance.
com.ibm.websphere.wim.Service service = new
LocalServiceProvider(“localhost”, 2809);
// Client application call create API to creates a new entry.
service.create(inputDataObject)
[0033] The capabilities of the present invention can be implemented in software, firmware, hardware or some combination thereof.
[0034] As one example, one or more aspects of the present invention can be included in an article of manufacture (e.g., one or more computer program products) having, for instance, computer usable media. The media has embodied therein, for instance, computer readable program code means for providing and facilitating the capabilities of the present invention. The article of manufacture can be included as a part of a computer system or sold separately.
[0035] There may be many variations to these diagrams or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
[0036] While the preferred embodiment to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described. | 4y
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FIELD OF THE INVENTION
[0001] This invention relates generally to medical devices and procedures, and more particularly to a method and system of deploying a stent-graft in a vascular system.
BACKGROUND OF THE INVENTION
[0002] Prostheses for implantation in blood vessels or other similar organs of the living body are, in general, well known in the medical art. For example, prosthetic vascular grafts formed of biocompatible materials (e.g., Dacron or expanded, porous polytetrafluoroethylene (PTFE) tubing) have been employed to replace or bypass damaged or occluded natural blood vessels. A graft material supported by framework is known as a stent-graft or endoluminal graft. In general, the use of stent-grafts for treatment or isolation of vascular aneurysms and vessel walls which have been thinned or thickened by disease (endoluminal repair or exclusion) are well known. Many stent-grafts, are “self-expanding”, i.e., inserted into the vascular system in a compressed or contracted state, and permitted to expand upon removal of a restraint. Self-expanding stent-grafts typically employ a wire or tube configured (e.g. bent or cut) to provide an outward radial force and employ a suitable elastic material such as stainless steel or Nitinol (nickel-titanium). Nitinol may additionally employ shape memory properties. The self-expanding stent-graft is typically configured in a tubular shape of a slightly greater diameter than the diameter of the blood vessel in which the stent-graft is intended to be used. In general, rather than inserting in a traumatic and invasive manner, stent-grafts are preferably deployed through a less invasive intraluminal delivery, i.e., cutting through the skin to access a lumen or vasculature or percutaneously via successive dilatation, at a convenient (and less traumatic) entry point, and routing the stent-graft through the lumen to the site where the prosthesis is to be deployed.
[0003] Intraluminal deployment is typically effected using a delivery catheter with coaxial inner (plunger) and outer (sheath) tubes arranged for relative axial movement. The stent graft is compressed and disposed within the distal end of an outer catheter tube in front of an inner tube. The catheter is then maneuvered, typically routed though a lumen (e.g., vessel), until the end of the catheter (and the stent-graft) is positioned in the vicinity of the intended treatment site. The inner tube is then held stationary while the outer tube of the delivery catheter is withdrawn. The inner tube prevents the stent-graft from being withdrawn with the outer tube. As the outer tube is withdrawn, the stent-graft radially expands so that at least a portion of it is in substantially conforming surface contact with a portion of the interior of the lumen e.g., blood vessel wall.
[0004] Most stent-graft deployment systems use only a semi-rigid sheath in the deployment systems. The semi-rigid sheath provides columnar strength to advance the system through access vessels in the body. Unfortunately, the semi-rigid sheath may tend to kink in areas having tight radiuses such as the thoracic arch. Such kinking can increase the deployment force required to place a stent-graft in a target area or even prevent deployment completely. Even if kinking can be avoided, use of a semi-rigid sheath may still increase the pushing force needed to overcome frictional resistance required to deploy the stent-graft to the target area.
[0005] One attempt to overcome this problem by W. L. Gore utilized a flexible jacket that deploys the stent-graft with a ripcord that opens the jacket along the longitudinal axis of the flexible jacket, e.g., U.S. Pat. No. 6,315,792. Another single step sheath release initiation is disclosed in U.S. Pat. No. 5,824,041 to Lenker. Unfortunately, these methods introduced a separate non-integrated sheath into the system into the femoral artery and further failed to provide the desired control during deployment. Thus, a need exists for a method and deployment system that avoids kinking (reductions in area or change in shape which creates resistance to deployment) and reduces forces during deployment of stent-grafts in areas having tight radiuses, yet provides appropriate control and in addition provides flexibility during advancement in areas having tight radiuses.
SUMMARY OF THE INVENTION
[0006] In one aspect according to the present invention, a stent-graft deployment system comprises a retractable primary sheath, a secondary sheath initially covered by the retractable primary sheath, a stent-graft initially retained within the secondary sheath, and a deployment means for deploying the stent-graft. The secondary sheath is more flexible than the retractable primary sheath. The retractable primary sheath can contain the stent-graft in a first constrained small diameter configuration and the secondary sheath can be disposed within the retractable primary sheath and also contain the stent-graft. When the primary sheath is removed from around the stent-graft, the flexible secondary sheath contains the stent-graft in a second constrained small diameter configuration. The removal of the secondary sheath releases the stent-graft from a radial constraint so that stent-graft deployment may proceed.
[0007] In another aspect according to the present invention, a stent-graft deployment system before deployment includes a stent-graft constricted within the flexible secondary sheath, a semi-rigid sheath around the flexible secondary sheath, the semi-rigid sheath being retracted to expose the flexible secondary sheath, and the flexible secondary sheath being retractable such that the stent-graft expands as the flexible secondary sheath is retracted.
[0008] In another aspect according to the present invention, a device for implanting a radially self-expanding endoprosthesis comprises an outer sheath which is more rigid and axially maneuverable than an inner sheath. In one configuration the outer sheath is disposed over the inner sheath. While in a second position the outer sheath is retracted to expose the inner sheath. The device further comprises an axially maneuverable elongated catheter coupled to the inner sheath. In a first position the inner sheath retains the radially self-expanding endoprosthesis. As the inner sheath is moved to a second position by for example pulling the proximal end of the inner sheath, the radially self-expanding endoprosthesis is deployed.
[0009] A stent-graft deployment system, includes a stent-graft and a catheter having a catheter shaft having a tip; a retractable primary sheath and a retractable flexible secondary sheath. In a predeployed condition the flexible secondary sheath contains the stent-graft in a second constrained small diameter configuration around the catheter shaft at a stent graft location of the catheter near the tip and within the retractable primary sheath. When the primary sheath is retracted from around the stent-graft, the flexible secondary sheath containing the stent graft in the second constrained small diameter configuration is exposed and an end portion of the catheter from an end of the tip to a retracted end of the primary sheath has substantially reduced resistance to bending as compared to when the primary sheath is covering the stent graft location of the catheter. Removal of the secondary sheath releases the stent-graft from a radial constraint so that stent-graft deployment occurs as the secondary sheath releases. Removal of the retractable secondary sheath occurs through a secondary sheath retraction handle connected to a proximal end of the retractable flexible secondary sheath, such that retraction of the secondary sheath retraction handle causes a proximal end of the retractable flexible secondary sheath to be pulled along a catheter longitudinal axis toward a proximal end of the catheter. Pulling of the proximal end of the retractable flexible secondary sheath tensions the retractable flexible sheath to retract the sheath along the catheter longitudinal axis to cause progressive deployment of the stent graft from a distal end of the stent graft.
[0010] In another aspect according to the present invention, a method of deploying a stent-graft includes the steps of loading the stent-graft deployment system with a stent-graft, tracking the stent-graft deployment system over a guide wire to a location before a target area which may include a curved portion, and retracting a primary sheath to expose a secondary sheath within said primary sheath while the primary sheath is retracted or held as the secondary sheath is exposed, the stent-graft is moved to its location within the target area or moved until its location within the target area is confirmed. The method further includes the steps of further tracking the stent-graft deployment system to place the secondary sheath in the curved portion of the target area, and retracting the secondary sheath to at least partially deploy the stent-graft in the target area and may include releasing the stent-graft from the delivery system using a release mechanism
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a plan view of a stent-graft deployment system without a stent-graft in accordance with the present invention (not to scale);
[0012] FIG. 2 is a close up schematic plan view of the end of the deployment system of FIG. 1 having a loaded stent-graft;
[0013] FIG. 3 is a close up schematic plan view of the end of the deployment system of FIG. 1 showing an alternative retention mechanism with a loaded stent-graft;
[0014] FIG. 4 illustrates the stent-graft deployment system of FIG. 1 with a primary sheath covering a secondary sheath (in dashed lines);
[0015] FIG. 5 illustrates the stent-graft deployment system of FIG. 1 with the primary sheath retracted and the secondary sheath exposed;
[0016] FIG. 6 illustrates the stent-graft deployment system of FIG. 1 with the primary sheath retracted and the secondary sheath partially retracted;
[0017] FIG. 7 illustrates the stent-graft deployment system of FIG. 1 with the primary sheath retracted with the secondary sheath almost completely retracted;
[0018] FIG. 8 illustrates the stent-graft deployment system of FIG. 1 with the secondary sheath completely retracted and the stent-graft fully deployed;
[0019] FIG. 9 is a flow chart illustrating the steps of a method in accordance with the present invention;
[0020] FIG. 10 is a schematic diagram illustrating the stent-graft deployment system initially inserted to a location adjacent (before) a tight curved target area;
[0021] FIG. 11 is a schematic diagram illustrating the stent-graft deployment system showing the primary sheath retracted and the secondary sheath exposed;
[0022] FIG. 12 is a schematic diagram illustrating the stent-graft deployment system with the secondary sheath which is exposed advanced into the tight curve;
[0023] FIG. 13 is a schematic diagram illustrating the stent-graft deployment system with the secondary sheath which has been advanced into the curve is partially retracted and the stent-graft is partially deployed;
[0024] FIG. 14 is a schematic diagram illustrating the stent-graft deployment system with the secondary sheath being completely retracted and a stent-graft being fully deployed; and
[0025] FIG. 15 is a schematic diagram illustrating the stent-graft fully deployed with the stent-graft deployment system removed in accordance with the present invention.
DETAILED DESCRIPTION
[0026] FIGS. 1-3 show portions of a stent-graft deployment system 10 . FIG. 1 illustrates the system 10 without a stent-graft while FIGS. 2 and 3 show close up views of the deployment system tip which are loaded with a stent-graft 15 , 15 a . This system could also deploy a stent alone or some other form of endoprosthesis. The subsequent use of “stent-graft” herein should be understood to include other forms of endoprosthesis. Ideally, the stent-graft deployment system 10 comprises a tapered tip 12 , 12 a , 12 b that is flexible and able to provide trackability in tight and tortuous vessels, and can bend easily once the primary sheath 20 is retracted. Other tip shapes such as bullet-shaped tips could also be used.
[0027] The system 10 includes a primary sheath 20 (preferably made of a semi-rigid material such as PTFE) initially covering a secondary sheath 14 (preferably made of woven polyethylene terephthalate (PET)). The secondary sheath 14 is more flexible than the retractable primary sheath 20 . The deployment system 10 is able to separately retract the primary and secondary sheaths.
[0028] The primary sheath should have enough stiffness to provide adequate trackability and column strength as the system 10 tracks through tortuous vessels to avoid buckling or kinking. The secondary sheath utilizes its greater flexibility (at the expense of column strength) to improve trackability and pushability, particularly through areas having tight radiuses. So, where prior deployment systems utilizingjust a semi-rigid primary sheath were prone to kinking while tracking through an area with a tight radius. Use of the secondary sheath avoids kinking or changes in shape and reduces resistance to deployment (reduced advancement force) while tracking through vessels with tight curves.
[0029] The deployment system 10 also includes a stent-graft 15 initially retained within the secondary sheath 14 . As described herein, the stent-graft 15 is preferably a self-expanding, Nitinol/Dacron stent-graft system designed for endovascular exclusion of Thoracic Aortic Aneurisms (TAA). The deployment system 10 includes a cup 16 as shown in FIG. 2 or alternatively steel runners 17 as shown in FIG. 3 that eventually release the stent-graft by its mere self-expansion to act as a means for retaining the stent-graft 15 in place during deployment. Although the means for retaining shown in FIG. 3 is on the “backend” of the stent-graft, it can alternatively or additionally be on a “tip end” of the stent-graft and attached to one or more of several coaxial tubes. A handle or a hub 22 is fixed to the primary sheath 20 , a second handle or hub ( 24 ) near a proximal end of the stent-graft deployment system 10 is fixed to the secondary sheath, and a catheter shaft including a shaft handle 26 is connected to and aids the advancement of the system 10 and acts as a deployment means. In addition, the deployment system 10 shown includes a flush port 28 and a radiopaque marker 18 allowing for accurate positioning of the delivery system prior to deployment of the stent-graft in the proximal position.
[0030] Referring to FIGS. 4-8 and FIGS. 10-15 , the stent-graft deployment system 10 is shown in various stages as it is advances over a guide wire 111 (as shown in FIGS. 10-14 ) and the stent-graft is deployed. FIGS. 4-8 , in particular, illustrate the stent-graft deployment system 10 as it would operate or function outside or apart from the body. FIGS. 10-15 illustrate the stent-graft deployment system as it would operate when tracking over a guide wire 111 within a body and particularly through a target area (vessel) having a tight curvature or radius ( 21 ). FIGS. 4 and 10 both illustrate the stent-graft deployment system 10 with the primary sheath 20 covering the secondary sheath 14 . The flexible secondary sheath 14 is arranged within the semi-rigid sheath 20 when the semi-rigid sheath 20 is in a non-retracted position as shown in FIG. 4 .
[0031] As shown in FIG. 5 , the stent-graft 15 is constrained solely by the flexible secondary sheath 14 and further illustrates a handle or hub 22 coupled to the semi-rigid sheath 20 serving as a first arrangement for retracting the semi-rigid sheath 20 and exposing the flexible secondary sheath 14 as well as an inner tube 25 coupled to the flexible secondary sheath 14 serving as a second arrangement for retracting the flexible secondary sheath and enabling the stent-graft to expand. It should be noted that the exposed portion of the flexible secondary sheath 14 could have a diameter larger than the semi-rigid primary sheath 20 that surrounded the flexible secondary sheath 14 previously. The larger diameter of the exposed portion of the flexible secondary sheath 14 is a contributory factor in reducing the force needed to retract the secondary sheath. Once the flexible secondary sheath 14 is exposed, the end of stent-graft deployment system 10 beyond the semi-rigid sheath has greater flexibility (than the portion of the system within the semi-rigid sheath 20 ) as it tracks across the guidewire.
[0032] The first arrangement described above could comprise (as previously mentioned) the handle or hub 22 coupled to the semi-rigid sheath 20 enabling the relative axial movement of the semi-rigid sheath 20 over a remainder of the stent-graft deployment system and the second arrangement could comprise an inner tube 25 coupled to the flexible secondary sheath 14 that enables relative axial movement of the flexible secondary sheath 14 relative to the semi-rigid sheath 20 and the longitudinal axis of the catheter. Such as where operation of the second handle 24 causes axial pulling of the proximal end of the flexible secondary sheath 14 , to create a tension in the material/fabric of the secondary sheath to cause retraction that causes the cylindrically configured sheath to retract along the longitudinal axis of the catheter to provide a substantially circularly uniform deployment of the stent graft starting at its distal end (relative to the catheter).
[0033] In any event, once the secondary sheath 14 is exposed or outside the primary sheath, the system 10 can be advanced over the guide wire 111 with a lower advancement force since the secondary sheath is designed to be quite flexible particularly in areas with tight radiuses ( 21 ) as shown in FIG. 12 . The tight arch 21 is meant to represent any area or vessels with tight radiuses such as the thoracic arch.
[0034] Referring to FIGS. 6 and 13 , in each instance the primary sheath has been retracted and the secondary sheath is shown partially retracted with the stent-graft 15 being partially deployed. As the secondary sheath retracts, more and more of the stent-graft is deployed as shown in FIGS. 6-8 and FIGS. 13-15 .
[0035] FIGS. 8 and 14 illustrate the stent-graft deployment system 10 with the secondary sheath 14 completely retracted and the stent-graft 15 fully deployed. In FIG. 15 the stent-graft deployment system 10 has been removed.
[0036] The stent-graft deployment system 10 can also be thought of as a device for implanting a radially self-expanding endoprosthesis 15 having an outer sheath 20 . As previously explained, the outer sheath 20 is more rigid and axially maneuverable relative to an inner sheath 14 and wherein the outer sheath 20 is disposed over the inner sheath 14 in a first position (as shown in FIG. 5 ) and exposes the inner sheath 14 in a second position (as shown in FIGS. 6-8 ). The system 10 can also include an elongated catheter 25 coupled to the inner sheath 14 , wherein the inner sheath 14 is constructed to retain the radially self-expanding endoprosthesis 15 in a first position and enable deployment of the radially self-expanding endoprosthesis 15 in a second position.
[0037] Referring to FIG. 9 , a flow chart illustrates a method 100 of deploying a stent-graft includes the steps of providing a stent-graft deployment system with a stent-graft 102 , tracking the stent-graft deployment system over a guide wire to a location before a target area 104 , which may include a curved portion, and retracting the primary sheath to expose a secondary sheath within the target area while the primary sheath is retracted or held as the secondary sheath is exposed 106 . The stent-graft is moved to its location within the target area or until its location within the target area is confirmed. It should be noted that once the primary sheath is retracted and the secondary sheath is exposed, the secondary sheath (being of a relatively more flexible material than the primary sheath) will provide greater flexibility in tracking through the remainder of the target area regardless of the curvature or tortuous nature of the vessel. The method further includes the steps of further tracking the stent-graft deployment system to place the secondary sheath in the curved portion of the target area 108 , and retracting the secondary sheath to at least partially deploy the stent-graft in the target area 110 . This step may include deploying or releasing the stent-graft from the delivery system using a release mechanism 112 .
[0038] The device may also be considered to have a first predeployment configuration wherein said first and second sheaths surround the stent graft to be deployed, and a second partial deployment configuration where the primary sheath is fully retract so that the primary sheath no longer constrains the stent graft to be deployed, while the secondary sheath still constrains the stent graft to be deployed, and third fully deployed configuration where said stent graft is fully released from the primary and secondary sheaths. Wherein the relative movement of the tubular (substantially cylindrical sheaths) is such that the axial centerline of the cylinder forming the sheaths is moved without the sheaths being everted between their respective predeployment configurations and their respective post deployment configurations such that the axial centerline of the cylinder of each sheath moves in substantially one motion (in a linear movement along a curving path) along the axial centerline of the catheter along which it is moved
[0039] The present configuration is well suited for introducing the stent-graft deployment system into a femoral artery and advancing the stent-graft deployment system through an iliac artery into the aorta for repair of an aortic aneurysm and more specifically in tracking the stent-graft deployment system through a portion of an thoracic arch when the secondary sheath has been exposed after the retraction of the primary sheath and without any kinking of the primary sheath.
[0040] Additionally, the description above is intended by way of example only and is not intended to limit the spirit and scope of the invention and it equivalent as understood by persons skilled in the art. | 4y
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FIELD OF INVENTION
The present invention generally relates to insulation for buildings and, more particularly, to insulation members designed to reflect radiant heat energy. More particularly the present invention is directed to a radiant heat reflective panel formed so as to be insertable in press fit relation between adjacently disposed roof rafters in a ventilated attic of a building. The radiant barrier may be used with or without traditional bulk insulation.
BACKGROUND OF INVENTION
Radiant barriers are installed in buildings to reduce summer heat gain and winter heat loss, and hence to reduce building heating and cooling energy usage. The potential benefit of attic radiant barriers is primarily in reducing air-conditioning cooling loads in warm or hot climates. Most of the known radiant barriers are composite members consisting of a thin sheet or coating of a highly reflective material, such as aluminum, applied to one or both of opposite face surfaces of a suitable substrate material. The substrate maybe kraft paper, plastic films, cardboard, or the like. Some products are fiber reinforced to increase the durability and/or stiffness. The reflective panel may also be comprised in whole or in part of a plastic, paper, or corrugated sheet of material covered by a reflective material such as aluminum or other metal foil or even a reflective coating such as a metallic paint.
Radiant barriers work by reducing heat transfer by thermal radiation across the air space between the roof deck and the attic floor and may be installed in attics in several configurations. The simplest method of application is to lay the radiant barrier directly on top of existing attic insulation, with the reflective side up. Another way is to attach it near the roof and a still further way is to drape the radiant barrier over the tops of the rafters before the roof deck is applied. Another variation is to attach the radiant barrier directly to the underside of the roof deck.
The following references, directed to reflective insulation panels, rafter vents, radiant barriers and the like reference, are considered to be only of interest: U.S. Patent Publication 2008/0134608 by Snyder published Jun. 12, 2008 Snyder; U.S. Patent Publication 2007/0259155 by Zupon et al. published Nov. 8, 2007; U.S. Pat. No. 7,302,776 by Duncan et al. granted Dec. 4, 2007; U.S. Pat. No. 6,926,785 by Tanzer et al. granted on Aug. 9, 2005; U.S. Pat. No. 6,800,352 by Hejna et al. granted Oct. 5, 2004; U.S. Pat. No. 6,444,286 by MacKenzie granted Sep. 3, 2002; and U.S. Pat. No. 6,346,040 granted on Feb. 12, 2002.
In residential homes typically the roof structure is formed of materials which inherently have minimal thermal insulating and emissivity barrier properties. Therefore, heat transfer through the roof structure from the outdoors to the interior space of for example, a home, particularly during the summer months, is a problem to the home owner. Either the home owner undergoes severe discomfort due to the elevated temperatures inside the house or they must pay a high price for utilities including installation and operation of an air conditioning system. The insulating solar or heat emitting properties of a structural roof have undergone limited improvements. Excess heat transfer is generated on a daily basis at least in the summer months penetrating into the interior of building materials such as sheet rock and insulation and cause unwanted elevated temperatures within the interior living space. Thus under conventional home construction conditions, the air temperature in attics and ceilings can be raised to about 140 degrees F. or higher.
SUMMARY OF INVENTION
With an increasing emphasis on energy efficiency and “green” building materials, the combination of a radiant barrier and rafter vent is the solution.
The radiant barrier rafter vent (“RBRV”), can be produced from recycled aluminum material and have the ability to be 100 percent recyclable. The foil or sheet reflects and/or limits a substantial amount of the radiant energy from passing through the barrier. The reflective metal foil utilized in at least one preferred embodiment of the invention is composed of a non petroleum product and is environmentally friendlier than foam, plastic, paper, or most other man made materials.
Addition of the radiant barrier rafter vent under the roof deck after construction eliminates the inherent problem with moisture from rain on the roof decking during construction by allowing air circulation from the soffit to the ridge via the air cavity between the vent and roof deck after construction. Radiant barriers are recommended to be installed in buildings by: RIMA International, Rocky Mountain Institute, Florida Solar Energy Center, and the Department of Energy. A radiant barrier installed in a home's roof deck is southern climates is among the top energy saving items to be considered into today's energy saving projects.
The present invention comprises, consists essentially of, or consists of a heat reflective elongate panel insertable in friction fit between adjacently disposed spaced apart roof rafters and/or held in position with lateral support wires in cooperative engagement with the rafters, the panel having first and second laterally spaced apart longitudinally extending creased sections and panel strengthening formations disposed there between, the creased sections being disposed adjacent respective opposite longitudinal marginal edges of the panel permitting compressing the same a selected amount in a direction transverse to its length and wherein the panel longitudinal marginal edges are formed into panel strengthening ribs.
More particularly, the present invention comprises, consists essentially of, or consists of: an elongate radiant heat reflective panel of a flexible material such as a paper, plastic, metal or other pliable material having a heat reflective surface for instance such as chrome or aluminum. One preferred material is a sheet of aluminum of a selected thickness having longitudinal creases formed on selected portions thereof permitting compressing the panel a selected amount in a direction transverse to its length and panel stiffening protrusions spaced apart from one another on the remainder of the panel. The panel may include creases located proximate each of opposite longitudinal edges of the panel. Moreover, the protrusions can include a major rib extending transversely across the panel from one to the other of the creases at a position proximate each of opposite ends of the panel. A plurality of minor spaced apart ribs can be located between the major ribs and opposite longitudinal edges of the panel can be folded over providing stiffening ribs. The marginal edge stiffening ribs of the panel can be tubular and the panel can utilize major ribs having a narrow groove in each of opposite ends thereof. The panel can include a curved springy wire for each of the major ribs, the wires having opposite end portions thereof nested in the narrow grooves of the major rib associated therewith and piercing through the longitudinal creases. Creases provide accordion-like parallel pleated sections spaced apart from one another in a direction transverse to the length of the panel.
An object of the present invention is to provide a radiant heat reflective panel that is insertable in press fit relation between roof rafters of a building and/or be held in position or reinforced with a lateral wire extending there through (preferably within a groove formed therein) for locking the panel in place in a selected position between the rafters spaced apart from the roof.
A further object of the present invention is to provide a heat reflective panel of relatively thin aluminum sheet formed to provide suitable rigidity and including longitudinal creases compressible in a direction transverse to the length of the panel.
It is another object of the present invention to provide a panel including a plurality of small holes formed therein providing ventilation and sound deadening features.
Is another object of the invention to provide a coating on the underside of the panel to provide a sound deadening effect.
It is another object of the present invention to optionally provide a coating of paper, corrugated material, foam, dense foam, cellular material or combinations thereof to aid in insulation and/or to produce a sound deadening effect.
In keeping with the forgoing there is provided in accordance with the present invention an elongate radiant heat reflective panel comprising a sheet of aluminum of selected minimum thickness formed to provide longitudinal creases on selected portions thereof permitting compressing the panel a selected amount in a direction transverse to its length and protrusions spaced apart from one another stiffening the remainder of the panel. The creases are disposed preferably proximate opposite longitudinal marginal edges of the panel and the protrusions disposed there between. In the preferred form the protrusions are ribs. The panels are insertable in press fit relation between the roof rafters and preferably secured via curved springy wires that space the panel a preselected distance from the roof decking.
At least one preferred embodiment comprises, consists essentially of and/or consists of a radiant barrier panel having an elongated heat reflective sheet of reflective material of selected thickness having longitudinal creases formed on selected portions thereof permitting compressing the panel a selected amount in a direction transverse to its length and panel stiffening protrusions spaced apart from one another on the remainder of the panel including at least one longitudinal lateral support member cooperatively engaging and removably holding said sheet in a selected position disposed between a pair of roof support members spaced apart from a roof a selected distance.
Other objects, features, and advantages of the invention will be apparent with the following detailed description taken in conjunction with the accompanying drawings showing a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the several views and wherein:
FIG. 1 is an oblique view of the device showing a portion of some components of a truss roof structure but with the radiant heat reflective panel in accordance with one aspect of the present invention just prior to being inserted between the two adjacently disposed roof rafters;
FIG. 2 in an oblique view showing a portion of some components of a truss roof structure and a radiant heat reflective panel provided in accordance with one aspect of the present invention and secured by an anchoring means in accordance with another aspect of the present invention;
FIG. 3 is essentially an end view of FIG. 2 ;
FIG. 4 is a view showing a bottom face of an individual panel;
FIG. 5 is a right hand side view of FIG. 4 ;
FIG. 6 is an enlarged view of the encircled portion of FIG. 3 but with the rafter omitted;
FIG. 7 is a bottom view of FIG. 6 ;
FIG. 8 is a left hand side elevational view of FIG. 6 ;
FIG. 9 is an enlarged view of the encircled portion of FIG. 3 but with the rafter omitted showing a thin layer of a sound absorbing material adhering to the bottom of the panel;
FIG. 10 is an enlarged view of the encircled portion of FIG. 3 but with the rafter omitted showing a layer of an insulating material adhering to the bottom of the panel; and
FIG. 11 is a perspective end view of the panel having a lateral wire inserted laterally through lateral grooves formed in the outer ribs of the panel holding the panels stable between a pair of rafters wherein the wires are bowing upward toward the roof and normal to the panel providing means for adjusting the tension of the panels support wire means and preventing the wire from rolling over.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 & 2 there is illustrated a few components of a portion of a building roof structure 10 of wood construction that includes parallel, adjacently disposed, roof rafters 11 , 12 covered over with and supporting sheeting material 13 such as plywood, OSB (oriented strand board) or the like. The outer surface 14 of the sheeting material, in a completed building, would have a weather proof covering consisting of tiles, shingles, sheet metal roofing or the like overlying a lapped layer of tar paper non of which for reasons of simplicity is shown. In a conventional residential building having a roof of wood construction the roof rafters are spaced 16 inches unless constructed using trusses, wooden J-joints, conventional rafters or any other rafter frame utilizing spaced apart longitudinal members to support the roof, which can be for example 24 inches center-to-center. In the embodiment illustrated the spacing assumed is 24 inches in which case the distance between the faces of adjacent roof rafters is 22.5 inches. It is contemplated that the invention can be fabricated to fit between rafters of any width.
A panel 20 , provided in accordance with a principal aspect of the present invention, is shown generally in FIGS. 1 to 5 . In FIG. 1 the panel 20 is shown just prior to being inserted between the roof rafters and in this uncompressed state has an overall width that is somewhat greater than the spacing between the opposing faces of the adjacently disposed roof rafters 11 , 12 . By way of example the distance between the roof rafters is 22.5 inches and the overall width of the panel approximately 23.5 inches. In FIG. 2 the panel is in a compressed state in its final position between the adjacently disposed roof rafters 11 , 12 . Preferably, a lateral wire or other stiff flexible member such as a fiberglass rod is inserted through grooves formed in the panel for structural stability. It adds stiffness and stability to the panel and aids in keeping the wire from rolling over. The panel 20 in this position has a top face 22 spaced a selected distance downwardly from the lower face of the roof decking 13 and a bottom face 21 facing the open attic space of the building above the attic floor.
Panel 20 is formed from a sheet of aluminum having a preselected thickness of from 0.001 to 0.020 inches, and more preferably in the range of 0.004 to 0.008 inches. The sheet is shaped to provide suitable stiffness making it semi-rigid as well as permitting some compression transverse to its length the latter of which allows squeezing the panel for a press fit between the two adjacently disposed roof rafters. The sheet is stiffened length wise by creases extending lengthwise of the panel and these creases allow one to compress the panel. The creases are shown as accordion-like pleated longitudinal portions 23 , 24 proximate respective opposite longitudinal marginal edges of the panel. The pleats include planar narrow strips 27 , 28 and 29 where strips 27 , 28 are joined by a generally rounded fold 25 and the strips 28 , 29 by a rounded reverse fold 26 . Other fold arrangements maybe used providing they permit lateral compression of the panel. The undercut groove 31 disposed on each side of the rounded fold 25 provide means for insertion of the longitudinal members or fingers of an installation tool used to snap into place for installation in hard to reach areas.
The outer terminal edge of the outer strip 29 can be rolled upon itself one or more turns defining a curl and providing the panel with a pair of strengthened outer rod-like or tube-like marginal ribs 30 . The roll formed edge readily slides on the face of the rafter facilitating inserting the panel between adjacently disposed roof rafters. If desired the panel can be anchored to the roof rafters by fasteners such as tacks, staples or the like passing through, adjacent and/or straddling the rolled edge 30 .
The outer strip 29 can for example be disposed at an angle of approximately 45 degrees to the major portion of the sheet located between the according-like pleated marginal portions 23 , 24 . The pleating permits compressing the panel in a direction transverse to its length an amount sufficient to fit into the spacing between adjacently disposed trusses which as indicated above maybe about 1 inch less than the initial width of the panel before being inserted into position.
Panel 20 has major transverse ribs 32 , 33 spaced inwardly a selected distance from respective opposite ends thereof and a plurality of secondary spaced apart ribs 35 disposed there between. Ribs 32 , 33 project upwardly toward the lower face of the roof sheeting and ribs 35 project downwardly. The ribs stiffen the central major portion of the panel located between the spaced apart pleated portions 23 , 24 . Ribs 35 may be used in combination with and/or replaced by other suitably spaced apart panel stiffening protrusions of any suitable shape and/or pattern. Such formations and the bending to form the previously described marginal pleating, i.e. longitudinal creases, can readily be formed by press forming or passing a plain sheet of aluminum between a pair of counter rotating rolls having appropriately mating formations on the surfaces thereof. Another preferred method of producing the panels is by forming the ribs and other features of the panels using a compression die.
FIGS. 6-8 illustrate some details of the panel and referring to these transverse rib 32 has a sloping end portion 36 with a narrow centrally disposed depressed portion providing a groove 37 that has a bottom wall 38 . The opposite end of the rib 32 is the same as are the opposite ends of rib 33 as shown in FIG. 4 .
The panels are inserted in overlapping series arrangement and extend from the top plate at the soffit to the ridge board in each of the spaces between adjacently disposed roof rafters in the attic of a building. Should moisture in the attic present possible condensation problems then the panels instead of having adjacent ends overlap can be spaced a selected distance from one another providing a gap that allows air in the attic space to mix with the air in the channel above the top face of the panel.
In accordance with a further aspect of the present invention the panel 20 is retained in position between the roof rafters by a pair of arched wire members 50 that provide the dual function of firstly spacing the top face of the panel downwardly a preselected distance from the lower face of the roof decking material and secondly securely anchoring the panels to the roof rafters. Each wire member is springy with an arch of approximately 1.25 inches and a cord length from one to the other of its terminal ends somewhat greater than the distance between the rafters. The terminal ends of the wires are cut at an angle providing a sharp chisel like tip 51 that readily penetrates the surface of the roof rafter and easily punctures through the panel pleats.
Opposite end portions of the wire pierce through the strips 28 , 29 of the creased sections 23 as best illustrated in FIG. 6 . The wire rests in the grooves 37 at opposite ends of the transverse rib associated therewith. These grooves stabilize the wires in a position where they are in a plane generally perpendicular to the plane of the central portion of the panel. As shown in FIG. 11 the panel has a lateral wire inserted laterally through lateral grooves formed in the outer ribs of the panel holding the panels stable between a pair of rafters wherein the wires are bowing upward toward the roof and normal to the panel providing means for adjusting the tension of the panels support wire means and preventing the wire from rolling over.
The spacing between the upper face of the panels and the lower face of the roofing deck leaves an open air flow passage 60 from the soffit to vent holes at or near the roof ridge discharging to atmosphere. The depth of such passage is predetermined by the curvature of the wire. If desired the wire instead of having a single curve as shown maybe formed with two or more contiguous curved sections in which case it would have two or more points of contact with the roof decking rather than a single contact point as indicated at 52 in FIG. 3 .
As shown in FIG. 9 a thin layer of a sound absorbing material adheres to the bottom of the panel 10 . It is contemplated that a film of a polymer, rubber, closed cell or other foam type material could be used as an insulating material or sound absorbing material. The sound deadening properties are important to achieve good acoustics and filter the sound of rain, etc. in construction projects wherein the roof may not be insulted such as a garage, shop, or barn. FIG. 10 shows a layer of an insulating material adhering to the bottom of the panel.
FIG. 11 illustrates an embodiment of the panel whereof a section of the panel includes perforations 105 which aid in dampening sound and could also provide ventilation depending upon the size of the perforations.
The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modification will become obvious to those skilled in the art upon reading this disclosure and may be made upon departing from the spirit of the invention and scope of the appended claims. Accordingly, this invention is not intended to be limited by the specific exemplifications presented herein above. Rather, what is intended to be covered is within the spirit and scope of the appended claims. | 4y
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FIELD OF THE INVENTION
[0001] The present invention relates to a power management system and method, and, more particularly, to power management of computing systems.
BACKGROUND TO THE INVENTION
[0002] The computing industry has developed a common interface for enabling robust operating system directed motherboard system configuration and power management (OSPM) of entire computer systems. The common interface definition and functionality manifests itself in the Advanced Configuration and Power Interface (ACPI) specification. The current version of the ACPI is version 2, having a release date of Jul. 27, 2000, together with the ACPI Errata version 1.3, Nov. 27, 2000, both of which are incorporated herein by reference for all purposes.
[0003] The ACPI specification defines a number of operating states for computer systems, such as, for example, desktop, mobile, workstations, servers and laptop computers. Currently, the ACPI specification defines five states, that is, states S 0 , S 1 , S 2 , S 3 and S 4 . Each of the five states represents a different state or degree of power consumption of an associated computer system. State S 0 represents the conventional operating state or working state in which the computer system is fully functional and is not in a power saving mode. The remaining states represent the system sleeping states in which the computer system has undertaken steps to reduce power consumption.
[0004] Of particular interest are the S 3 and S 4 states. The ACPI specification defines the behaviour of the S 3 state such that less power is consumed within the S 3 state as compared to the S 2 state. In the S 3 state, the processor does not execute instructions and the processor context is not maintained. The dynamic RAM context is maintained and power resources are held in a state that is compatible with the S 3 state. Devices associated with the computer system are operable such that they are compatible with the S 3 state, that is, only devices that solely reference power resources are in the ON state (all other devices are in the off or D 3 state). Devices that are enabled to wake the system, and that can do so from their current state, can initiate a hardware event that causes the system to transition to the S 0 state.
[0005] The ACPI specification defines the system behaviour in the S 4 state as follows. The S 4 state is logically lower than the S 3 state and is arranged to consume less power than the S 3 state. The processor does not execute instructions and the processor context is not maintained. RAM context is not maintained and power resources are in a state that is compatible with the S 4 state, that is, all power resources that supply system level power in the S 0 , S 1 , S 2 or S 3 states are in the OFF state. All devices are operable so as to be compatible with the current power resource states; that is, all devices are in the D 3 state when the system is in the S 4 state.
[0006] A system, upon entering the S 3 state or in preparation for entering the S 3 state, saves, for example, the data necessary for resumption of the normal working state, S 0 , to RAM. Therefore, it can be appreciated that upon wake-up from the state S 3 , the data saved to RAM can be accessed and restored relative quickly. Therefore, the S 3 sleeping state is known as a low wake-up latency sleep state. However, the S 3 state suffers from a major inadequacy in the event of a power failure that adversely affects the RAM such that the content of the RAM is lost. Such a power failure prevents a reliable transition to the working system state, S 0 , and a re-boot of the computer system may be necessary. It can be appreciated that the data of applications and system context will be lost under such circumstances. Furthermore, a relatively long period of time will elapse during the re-boot before the computer system reaches the working state, S 0 .
[0007] In contrast, the Operating System Directed Power Management software (OSPM) of the system, before entering the S 4 state, saves a significant amount of data to a non-volatile storage medium such as, for example, an HDD. Conventionally, data comprising the entire content of the RAM together with device register values are saved to a file, which is stored on the HDD This data is known as the system memory context.
[0008] Upon wake-up from the S 4 state, the OSPM of the system is responsible for restoring the system context. Therefore, a system transition from the S 4 state to the S 0 state involves a significant amount of data recovery. The content of a file, “HIBERFIL.SYS”, containing the S 4 data, is retrieved from the HDD. This file is used to restore the system context to how it was at the time of entering the state S 4 . Due to the need to access a relatively slow storage device, system context restoration is a relatively lengthy process. Therefore, the S 4 state is considered to be the longest wake-latency sleeping state. Since a non-volatile storage medium is used to store the recovery data, the S 4 system state will allow recovery from a power failure. However, the time taken to effect such a recovery is unacceptably long.
[0009] Still further, since the RAM can, in some systems, be as large as 128 MB or greater, it will be appreciated that a significant amount of time will be taken to save the RAM image, that is, system memory context, to the HDD. Furthermore, as the resident RAM of a machine increases, the amount of power required to save that RAM image to the HDD or to read the RAM image from the HDD also increases. If the file containing the RAM image is fragmented, this will lead to further delays in reading the file from or writing the file to the HDD. Also, the number of disk head seek movements is relatively high when accessing a fragmented file.
[0010] It is an object of the present invention at least to mitigate some of the problems of the prior art.
SUMMARY OF THE INVENTION
[0011] Accordingly, a first aspect of thc present invention provides a method for power management of a system, having a system context, comprising a first storage medium having a current system memory context, which includes data relating to the system context, and a second non-volatile storage medium; the first and second storage media having first and second data access times respectively such that the first data access time is less than the second data access time; the system being operable in a plurality of states, each state having an associated level of system power consumption; the method comprising the steps of: compressing data representing at least a portion of the current system memory context and outputting the compressed data for storage on the second storage medium to allow a transition to a first state of the plurality of states from a second state of the plurality of states; and placing the system in the second state; restoring the system context from the current system memory context stored within the first storage medium in response to detection of an event while the system is in the second state or, in the event that insufficient power was available to the system to maintain the second state, recovering the compressed data from the second storage medium; decompressing the recovered data and restoring the system memory context using the decompressed data.
[0012] Advantageously, embodiments of the present invention enable a power management system to be realised in which the amount of data that needs to be saved to preserve a system context is reduced as compared to the prior art.
[0013] Preferred embodiments restore the system context once the system memory context has been restored in response to detecting an appropriate event. The appropriate event may be, for example, detection of the actuation of an input device by the user.
[0014] Furthermore, embodiments allow, in the absence of a power failure, a relatively fast wake-up time from a sleep state.
[0015] A second aspect of the present invention provides a system, capable of having a system context, comprising a first storage medium having a current system memory context, which includes data relating to the system context, and a second non-volatile storage medium; the first and second storage media having first and second data access times respectively such that the first data access time is less than the second data access time; the system being operable in a plurality of states, each state having an associated level of system power consumption, the system further comprising: a codec to compress data representing at least a portion of the current system memory context; means to output the compressed data for storage on the second storage medium to allow a transition to a first state of the plurality of states from a second state of the plurality of states; and means to place the system in the second state; means to restore the system context from the current system memory context stored within the first storage medium in response to detection of an event while the system is in the second state or, in the event that insufficient power was available to the system to maintain the second state, means to recover the compressed data from the second storage medium; and means to restore the system memory context having decompressed the recovered compressed data using the codec.
[0016] Preferably, the first state is a working state in which the power consumption of the system is greater than that of the second state.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:
[0018] [0018]FIG. 1 shows schematically a power management environment according to an embodiment;
[0019] [0019]FIG. 2 illustrates schematically ACPI states and state transitions for a known power management system;
[0020] [0020]FIG. 3 depicts states and associated state transitions of a power management system according to a first embodiment;
[0021] [0021]FIG. 4 shows a flowchart of a power-off or sleep process according to an embodiment;
[0022] [0022]FIG. 5 shows an embodiment of parallel compression and storage of the data representing the system memory context; and
[0023] [0023]FIG. 6 depicts a flowchart of a recovery process to restore the system memory context following a power failure that occurred during a reduced power consumption state according to an embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] [0024]FIG. 1 illustrates schematically a power management environment 100 within which ACPI specification power management can be realised. The power management environment 100 comprises a client machine 102 having a system context 104 , a processor 105 and a RAM 106 having a RAM image 108 . The RAM image 108 comprises the content of the RAM 106 . In preparation for entering a reduced power consumption state, in which some or all of the devices (not shown) of the client machine 102 may be powered-down or placed in a reduced power consumption state, the device register values are transferred from the devices into RAM 106 to form part of the RAM image 108 . The device register values that are saved to RAM 106 are those values that would be lost in a reduced power consumption state. The RAM image 108 , together with the device register values, are known as the system memory context.
[0025] The client machine has a boot-time routine 110 that supports ACPI routines. For example, the client machine may have an ACPI compliant BIOS. The client machine has an operating system 112 , which is arranged to implement operating system directed power management (OSPM) using OSPM software 114 . The client machine may run various applications 116 and 118 . The boot-time routine 110 comprises a codec 110 ′ for compressing and decompressing data. The codec 110 ′ may be realised in the form of a software codec, a hardware codec, which may form part of the CPU or which may be a dedicated DSP, or a combination of both hardware and software.
[0026] Additional hardware and software functionality is provided in the form of power management event detection logic 120 , which detects events in response to which the current power state of the client machine may change to another state. For example, the user may depress an ON button 122 , in which case the client machine may effect a transition from a current sleeping state to a working state. Alternatively, the user may instigate a software shutdown of the client machine 102 in response to which the OSPM software 114 may effect a transition from the current state to a sleeping state.
[0027] The events that the power management event detection logic 120 may detect also include, for example, modem or other communication device related events, which signal to the power management event detection logic 120 that data is being received and the modem or communication device and the RAM should be suitably powered-up to allow reception of the data. The power management event detection logic 120 forwards notification of detected events to the wake-up and sleep logic 124 . The wake-up and sleep logic 124 , in conjunction with the OSPM software 114 , manages the preservation of the system memory context of the client machine 102 This, in turn, preserves the system context of the client machine 102 .
[0028] The data representing the system memory context is compressed using the codec 110 ′. The compressed data 130 is stored on a non-volatile storage medium 132 such as, for example, an HDD. The compressed data 130 can be retrieved in response to a request from the client machine 102 . Once the requested data has been retrieved from the HDD 132 , the data is decompressed using the codec 110 ′. The OSPM software 114 uses the decompressed data to restore or establish the system memory context, which, in turn, can be used to restore the system context 104 of the client machine 102 .
[0029] In preferred embodiments, the compressed data 130 may be a concatenation of a number of blocks of the data 128 , each of which represents a compressed portion of the system memory context. Alternatively, the data 130 may represent the whole of the system memory context that was compressed as a single block.
[0030] Referring to FIG. 2, there is shown a state diagram 200 of known power management states. The state diagram has five states, that is, states S 0 202 , S 1 204 , S 2 206 , S 3 208 and S 4 210 . The five states are briefly described below.
[0031] State S 0 ; While a client machine is in state S 0 , the client machine 102 is said to be in a working state. The behaviour of that state is defined such that a processor 212 , or, in a multi-processor system, the processors are, in one of a number of so-called processor states, C 0 214 , C 1 216 , C 2 218 , . . . , C N 220 , which each represent varying degrees of processor operation and associated power consumption. The processor maintains the dynamic RAM context. The operating system software 112 individually manages any devices 222 , such as first 224 and second 226 devices, connected to, or forming part of, the client machine. The devices can be in any one of four possible device states D 0 -D 3 , which, again, reflect varying degrees of power consumption. Any associated power resources are arranged to be in a state that is compatible with the device states.
[0032] State S 1 : The S 1 state 204 is a low wake-up latency sleeping state. In this state, no system context is lost (CPU or chip set) and the system hardware of the client machine maintains all system context.
[0033] State S 2 : The S 2 state 206 is also considered to be a low wake-up latency sleeping state. The S 2 state 206 is substantially similar to the S 1 state 204 but for the CPU and the system cache context being lost in the S 2 state, since, typically, the operating system is responsible for maintaining cache and processor context.
[0034] State S 3 : The S 3 state 208 is a low wake-up latency sleeping state where all system context is lost but for system memory context. The CPU, cache and chip set context are lost in this state. However, the system hardware maintains memory context and restores some CPU and L 2 configuration context. The S 3 state 208 was described greater in detail above.
[0035] State S 4 : The S 4 state 210 is the lowest power, longest wake-up latency sleeping state supported by ACPI. To reduce power consumption, preferably to a minimum, it is assumed that the hardware platform has powered-off all devices but platform context is maintained. The S 4 state 210 has been described in greater detail above.
[0036] [0036]FIG. 3 shows a state transition diagram 300 for a power management system according to an embodiment. It can be seen that the state transition diagram 300 comprises a working system state S 0 302 . Preferably, conventional states S 1 304 and S 2 306 are also supported. The states S 0 -S 2 , in preferred embodiments, are substantially identical in operation and realisation to the corresponding states described above in relation to FIG. 2 and as defined in current ACPI specifications.
[0037] Additionally, the state diagram 300 illustrates a new state, that is, a Safe S 3 /Quick S 4 state 308 (SS 3 /QS 4 ). The behaviour of the client machine 102 in the SS 3 /QS 4 can be characterised by the actions of saving, in a compressed form, substantially the same data, or at least a portion of that data, to the non-volatile storage medium 132 as that saved in the conventional S 4 state while concurrently maintaining in memory the same data as that maintained in the conventional S 3 state. Furthermore, in the SS 3 /QS 4 state only the RAM remains in a powered state while all other aspects of the system adopt substantially the same powered state of the conventional S 3 state. The compressed data is saved in a file that may be called “SYS_CONTEXT.SYS” or in a dedicated, reserved, storage area of the HDD 132 . Alternatively, embodiments may provide a dedicated disk partition (not shown) for storage of the data representing the system memory context. Preferably, such a dedicated partition would not be accessible by the user.
[0038] Therefore, if a power failure occurs while the client machine is in the SS 3 /QS 4 state 308 , loading and decompressing the SYS_CONTEXT.SYS file can restore the system memory context, which can be used to restore the system context. In contrast to the known power management state S 3 , if a power failure occurs, the system context at the time of power failure is recoverable.
[0039] Compressing the data representing the system memory context also bcars the additional benefit that the time taken to retrieve the SYS_CONTEXT.SYS file from the HDD 132 is reduced since the file contains fewer bytes than the system memory context from which it was derived. Having a smaller file to retrieve from the HDD will also result in reduced power consumption when reading the data from the HDD as compared to reading an uncompressed file representing the system memory context. The same applies in respect of writing the compressed data to the HDD 132 .
[0040] In preferred embodiments, the SYS_CONTEXT.SYS file is arranged to bc stored on the HDD 132 in an unfragmented form. When the file is stored in an unfragmented form, the number of disk head seek operations will be reduced as compared to writing or reading a fragmented SYS_CONTEXT.SYS file. This leads to further power saving during the read and write operations. Furthermore, the storage and retrieval of such an unfragmented file will be quicker than the storage and retrieval of a fragmented file containing the data representing the system memory context or the compressed system memory context. This may advantageously reduce the so-called “time to application” constraint that may be imposed by operating system vendors. The “time to application” is the time taken between a user instigating a boot of the client machine or recovery from a sleep state and the operating system having been loaded so that the user can instigate the loading and execution of an application.
[0041] It will be appreciated that the type of compression or encoding used will have some bearing upon the degree of data reduction realised. In a simple case, using, for example, run-length encoding, strings of bytes or bits of the same value are replaced, where conducive to data reduction, by a value representing the number of bits or bytes in a string and an indication of the value of the bits or bytes in the string. In the case of compressing bits, it is possible to store an indication of the value of the first bit, that is, a zero or one, followed by successive values representing the number of zeros or ones in successive strings. Each new value represents a toggling between the strings of zeros and ones.
[0042] It will be appreciated that the present invention is not limited to any particular type of compression. Embodiments can be realised in which any form of loss-less compression can be used to reduce the amount of data needed to support system context restoration.
[0043] It will be appreciated that saving the data to a remotely accessible HDD may be desirable in the case of, for example, a thin client, which uses remotely accessible non-volatile storage. Therefore, the time taken to recover from a power failure when using network drives is reduced as compared to using an uncompressed SYS_CONTEXT.SYS file in such a situation. Still further, the reduced file size will also reduce network traffic when writing or reading the SYS_CONTEXT.SYS file.
[0044] In the absence of a power failure, the system context, when waking from the SS 3 /QS 4 state, can be restored within a relatively short period of time. The relatively short period of time may be, for example, 5 seconds, that is, within a time scale that is comparable to the wake-up time for a conventional S 3 state. However, the embodiments provide the additional security of also being recoverable from a power failure, unlike the conventional S 3 state.
[0045] Preferably, once the system context or system memory context has been restored following a power failure, the system enters or resumes the SS 3 /QS 4 state. However, it will be appreciated that embodiments can be realised such that any one of the states could be entered upon recovery.
[0046] Referring to FIG. 4, there is shown schematically a flowchart 400 of an OFF process, that is, a process for notionally switching off the client machine that utilises the SS 3 /QS 4 state. Upon detection of a power-off event by the power management event detection logic 120 at step 402 , the OSPM software 114 , firstly, co-ordinates the compression of the data representing the system memory context, at step 404 , and, secondly, saves the compressed system memory context to the HDD 132 in the above mentioned file at step 406 . As will be appreciated from FIG. 5, the compression and storage processes, described in greater details later, are performed in parallel in a pipeline manner according to preferred embodiments. In step 408 , the client machine adopts the same power saving configuration as the conventional S 3 state. At step 410 , the client machine has power for the RAM and the front panel power LED (not shown) is switched off.
[0047] [0047]FIG. 5 shows schematically the processing 500 that is undertaken by the processor 105 and the HDD 132 in preparation for entering the SS 3 /QS 4 state 308 . At some point in time 502 , the client machine 102 is instructed to enter the reduced power saving state SS 3 /QS 4 . The processor 105 , using the codec 110 ′, compresses a first block 504 of the RAM image 108 . The block of RAM may be any desired size. However, preferred embodiments use 64 k blocks of RAM. The first compressed block 506 of the RAM image 108 is output for storage on the HDD 132 . While the first compressed block 506 of the RAM image 108 is being written to the HDD 132 , the processor 105 fetches and compresses a second 64 k block 508 of the RAM image 108 . The second compressed block 510 of the RAM image 108 is written to the HDD 132 . The remaining blocks 512 to 516 of the RAM image 108 are each compressed in turn and the corresponding compressed blocks 518 to 522 of the RAM image 108 are output to the HDD. This pipeline processing of fetching and compressing blocks of the RAM image 108 and writing the compressed blocks of the RAM image to the HDD 132 is continued until the whole, or at least a portion, of the RAM image 108 has been processed, that is, until the whole or at least useful portions of the RAM image 108 have been saved in a compressed form.
[0048] Once the RAM image 108 has been compressed and saved to the HDD 132 , the client machine 102 adopts the SS 3 /QS 4 state 308 at time 524 . If the client machine comprises a power LED located on the front panel, which is often conventional, to show that the client machine 102 is powered-up when the LED is on and powered-down when the LED is off, the power to the LED is switched-off at 526 Current systems also include a power LED on the motherboard to provide an indication that power is still being supplied to the client machine when the case has been removed. However, the state of such a motherboard LED should not be affected for safety reasons by embodiments of the present invention.
[0049] [0049]FIG. 6 shows a flowchart 600 of a process to recover from a power failure while the client machine 102 was in the SS 3 /QS 4 state. A power return event is detected by the power management event detection logic 120 at step 602 which causes the client machine to retrieve the previously stored data 130 representing the compressed system memory context from the HDD 132 at step 604 . The retrieved data 130 is decompressed using the codec 110 ′. The decompressed data is used to restore the system memory context at step 606 . Again, in preferred embodiments, steps 604 and 606 are performed in a pipeline parallel manner, that is, the processing is the converse of that shown in FIG. 5. At step 608 , the power configuration of the client machine 102 is arranged by the OSPM software 114 to adopt substantially the same power configuration as in the conventional S 3 state. In step 610 , the front panel LED is placed in the off state.
[0050] It will be appreciated that the processing for then entering the working state, having restored the client machine to the SS 3 /QS 4 state, is the same as that described with reference to FIG. 4. This arrangement, that is placing the client machine in a the state that it was in immediately prior to a power failure is convenient for the user. It is also thought that it will be less disconcerting for the user as compared to restoring the client machine to the working system state.
[0051] A transition from the conventional S 3 state to the working state, that is, state S 0 , takes approximately 5 seconds as does the transition to the S 0 state from the SS 3 /QS 4 state, which are both significantly quicker than the current 2040 second wake-up time for an S 4 to S 0 transition. However, the SS 3 /QS 4 state has the additional advantage of allowing a consistent or safe recovery from a power failure while the client machine 102 was in the power saving state SS 3 /QS 4 .
[0052] Although the above embodiments show a lack of support for S 3 and S 4 states, it will be appreciated that embodiments can be realised in which the S 3 and S 4 states are supported in addition to the states described. The states S 3 310 and S 4 312 are shown in FIG. 3 as being optionally supported by the dotted line. Furthermore, embodiments can be realised that have only three states, which are the working state, S 0 , the SS 3 /QS 4 state and a mechanical off state. Alternatively, embodiments can be realised which have only two states; namely, the working state S 0 and the SS 3 /QS 4 state.
[0053] Furthermore, even though the above embodiments have been described in terms of having a number of system states, the present invention is not limited to such system states. Embodiments can be realised in which other states such as, for example, Legacy states, mechanical-off states G 3 and soft-off S 5 states are also supported.
[0054] Although the above embodiments use an HDD as the non-volatile storage means, it will be appreciated that other forms of non-volatile storage may be used. For example, a flash-memory may be used to store the data to allow recovery from a power failure. Still further, remotely accessible non-volatile storage may be used in addition or instead of the locally accessible HDD for storing the compressed data representing the system memory context.
[0055] It will be appreciated that the decision to save the data representing the system memory context in compressed or uncompressed form may be influenced by the anticipated time taken to perform the compression and subsequent decompression. Within embodiments, it may be more effective, in some circumstances, to store the data representing the system memory context in native form. Such circumstances include, for example, a situation in which the system memory context data is relatively small and the compression and decompression times would increase, rather than decrease, the time taken to store and recover the data representing the system memory context.
[0056] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
[0057] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
[0058] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
[0059] The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. | 4y
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RELATED APPLICATION
This application is a continuation-in-part of our earlier filed U.S. patent application Ser. No. 285,617 filed July 21, 1981, now abandoned the entire disclosure and contents of which is incorporated hereinto by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention lies in the field of glass preforms for drawing fiber optical waveguides for optical communications technology.
2. Prior Art
A major goal in light waveguides for use on optical communications technology is to achieve the lowest possible attenuation and pulse spread. Good homogeneity of the glass comprising a waveguide is a prerequisite for a low attenuation and a certain radial profile of refraction is a prerequisite for the low pulse spread. The profile of a paraboloid is suitable as the refractive index profile. Given this profile, it is possible to largely compensate for differences of transit time between individual mode groups in multimode glass fibers, and, thus, to keep pulse spread low. Thereby, the refractive index profile must be very precisely observed.
Glass fibers with a desire refractive index profile can be manufactured in such a manner that a glass rod is first manufactured which exhibits a corresponding refractive index profile. The fibers are drawn from such rod in such a manner that the shape of the refractive index profile in the rod is retained in the fibers drawn therefrom.
Glass rods with refractive index profiles can be manufactured in a method of the type initially cited. The so-called CVD method which is included among the methods of the type initially cited is particularly suited for step-shaped radial refractive index profiles such as exist, for example, given core-jacket glass fibers with a constant refractive index in the core and a constant refractive index in the jacket. In a current method of this type, the glass layers are deposited on the inside wall of a glass tube and the tube thus coated on the inside is deformed (melted) into a rod from which the desired fibers can be drawn.
In order to so deposit the glass layers, a reactive gas mixture is conducted through the tube which is heated from the outside. The chemical reaction is thermally triggered in the inside in the heating zone, whereby a powder exhibiting the composition of a desired glass is produced, is deposited on the inside wall of the tube, and is clear-melted into a glass film in the heating zone. The refractive index of the deposited glass can be influenced by the composition of the reactive gas mixture. Glass rods with a step-shaped refractive index profile, particularly for core-jacket glass fibers which are manufactured with the CVD method, are distinguished by a high homogeneity of the glass and the fibers drawn from them are distinguished by a low attentuation.
Refractive index profiles with a continuous curve, which, for example, correspond to a paraboloid profile, can be achieved with the CVD method by means of depositing a multitude of glass layers with refractive indexes which differ slightly from one another.
Thereby, in the production of a desired refractive index profile with a continuous curve, particularly having the profile of a paraboloid, it has turned out that settle marks, or ripples, occur of such a type that the individual layers no longer exhibit the desired homogenous composition in radial direction. It has further turned out that it is not practical to eliminate such inhomogeneities like settle marks or ripples by means of increasing the plurality of glass layers to be deposited while reducing the layer thicknesses.
Moreover, the preforms produced with such a known method exhibit a central disruption of the refractive index, particularly a central refractive index drop which has a disadvantageous influence on the band width of the fiber optical waveguides drawn from such a preform. This disruption has an increasingly disadvantageous effect on the band width with increases in breadth of the central disruption zone. A discussion of the "Effects of profile deformations on fiber bandwidths" was given by D. Marcuse and H. M. Presby in Appl. Opt. 18(1979) pp. 3758-3763.
BRIEF SUMMARY OF THE INVENTION
The invention related in one aspect to a method for manufacturing a glass composite having a predetermined index of refraction wherein at least two glass layers are successively precipitated on a glass substrate body from a gas phase upon initiation of a thermal reaction and wherein the composition of the respective individual glass layers is selected in such a manner that the sum of the indices of refraction of the individual layers corresponds to the desired predetermined index of refraction of the composite consisting of the substrate and the associated layers. Preferably said substrate body is cylindrically shaped and such layers are deposited on interior walls thereof. The invention further relates to the glass structures so produced which have a predetermined refractive index profile, especially doped silica glasses, as more particularly described herein.
In another aspect, the invention relates to a method for treating interior surface portions of such a composite of layers with an etching gas before collapsing the glass tube to form a rod suitable for use as a preform for drawing fiber optical waveguides for optical communications technology. The invention further relates to the rods so produced which have a prodetermined refractive index profile.
An object of the present invention to provide a system whereby a method which is generally of the type above cited can be improved to avoid fluctuations of the refractive index.
Another object is to provide glass layers for core-jacket type glass fibers which layers are doped with fluorine and which are produced by following an improved method which is generally of the type above cited.
Another object is to provide an improvement in such known method of the type above cited wherein the central refractive index disruption can be made narrower and, by so doing, the band width of the corresponding fiber optical waveguides can be improved.
The invention involves the discovery that fluorine has an attenuating influence on fluctuations of concentration which occur when practicing a method of the type above cited which appear to produce the undesired fluctuations in the refractive index. Thus, the smoothing of the refractive index profile is not predominantly achieved by means of the superimposition of two wavy concentration profiles which cancel one another out, but, rather, is achieved by means to true attenuation of concentration fluctuations.
Other and further aims, objects, purposes, advantages, uses, and the like for the present invention will be apparent to those skilled in the art from the present specification.
DETAILED DESCRIPTION
Advantageously, an individual glass layer as taught by this invention is doped with fluorine during its precipitation by the teachings of the present invention. In this procedure, the fluorine is advantageously introduced into the glass in such manner that the reactive gas mixture, from which a glass layer is deposited upon the initiation of a thermal reaction, contains a gaseous compound which incorporates fluorine in its molecular structure. Preferred gas compounds contain fluoride. Also, preferred are gaseous compounds which, in addition to fluorine, only contain elements which themselves, or whose oxides, have no significant tendency to dissolve in glass. Examples of particulary suitable such fluorine compounds include sulfurfluorine compounds, fluorohydrocarbons, nitrogen-fluorine compounds, mixtures thereof, and the like. In particular, all sulfur and nitrogen fluorides, fluorine containing halogenated hydrocarbons and/or carbonyl fluoride come into consideration here. Sulfur hexafluoride has proven particularly advantageous and is presently much preferred.
However, a gas composition (including a mixture of gases), in addition to a gaseous compound containing fluorine can also incorporate an element whose oxides easily dissolves in glass. By so doing, a second doping of a glass layer to be deposited can ensue simultaneously with a fluorine doping. Examples of particularly suitable compounds for such utilization in such a gas composition include: silicon tetrafluoride, boron trifluoride, phosphorus pentafluoride, mixtures thereof, and the like. These gaseous componds can lead to SiO 2 , B 2 O 3 and P 2 O 5 dopings in a glass layer.
Preferably, glass layers each consisting of an alkali-free silica glass that is doped, or becomes doped, with one or more substances in addition to fluorine are deposited when practicing this invention. Thus, a silica glass which is only doped, or becomes only doped, with germanium and fluorine has proven particularly advantageous and is a presently and particularly preferred glass layer of this invention.
In addition to such a particularly preferred glass, a silica glass has also proven to be advantageous which is doped, or becomes doped, in addition to fluorine, with at least one of the oxides or fluoride of the further elements: Ge, Al, Ti, Ta, Sn, Nb, Zr, Yb, La, P, B, Sb, mixtures thereof, and the like.
With the technique of this invention, a new glass consisting of an oxide of a substance has also been created which is doped with fluorine and also with one or more further elements. Such a glass is excellently well suited for the manufacture of gradient fibers. This glass is further characterized by being alkali-free. A preferred such substance for such a glass is silica. In addition to being doped with fluorine, a particularly preferred such silica glass is further doped only with germania. Likewise suitable, however, is a silica glass which, in addition to being doped with fluorine, is at most also doped with at least one of the oxides of the further elements Ge, Al, Ti, Ta, Sn, Nb, Zr, Yb, La, P, B, Sb, mixtures thereof, and the like.
In this new glass, the fluorine functions as an oxygen substitute and exists as a fluorine bound to a substance or to one or more of the further elements. The fluoride reduces the refractive index of a glass, and, therefore, it can also be added to a glass intended for use in the jacket of a glass fiber.
An explanation of the relatively high fluctuations of concentration, and thus, of refractive index occurring without fluorine additive, seems to lie in the following observation (there is no wish to be bound herein by theory): In the precipitation from the gaseous phase with external heating which was undertaken, i.e, thermal reaction initiation, a partial de-mixing occurs in the arising glass layer because an oxide such as germania, which is more easily volatilized, precipitates further downstream in front of the burner placed at that location, and is then covered by glass which is lower in germanium dioxide. As already mentioned, it was observed that this effect cannot be eliminated practically by increasing the number of layers given a reduction of the layer thickness, this also being less attractive because of the limited heating capacity.
In addition to the significantly reduced pulse spread, which indicates a greater homogeneity of the glass contaminated with fluorine, it can be observed in an optical microscope that layers with fluorine additive are significantly more homogenous than layers without a fluorine additive. Analyses of the radial course of concentration with an electron microprobe have shown, as above mentioned, that the smoothing of the refractive index profile is not chiefly the result of the superimposition of two wavy concentration profiles, namely of the Ge and of the F profile, but rather that the fluorine has an attenuating effect on the germanium profile. With fluctuations below 5%, the latter already seems significantly more uniform resulting in the aforementioned, considerably increased, band width of such fibers. The better homogenation is to be attributed to the participation of volatile Si and Ge fluorides which have a lower difference in their transport properties than the oxides, and, accordingly, effect a more uniform precipitation from the gaseous phase.
As already mentioned, particularly coming into consideration as molecular gases containing fluorine are gases which, in addition to fluorine, only contain elements which themselves, or whose oxides, exhibit no significant tendency towards solution in the glass employed, here SiO 2 . In addition to SF 6 and also other sulfur fluorides, such as SO 2 F 2 , S 2 F 2 , SF 4 , S 2 F 10 as well, are especially fluorohydrocarbons, and fluorohalohydrocarbons, such as, for example, CCl 2 F 2 , as well as nitrogen trifluoride (NF 3 ) and carbonylfluoride (COF 2 ).
As likewise already indicated, however, fluorides of elements can also be employed whose oxides dissolve easily in glass, silica glass especially. Particularly coming into consideration for this purpose are SiF 4 , BF 3 and PF 5 . These substances lead to SiO 2 , B 2 O 3 and P 2 O 5 dopings.
By the term "doping", "doped", or equivalent, reference herein is had the addition of an impurity or impurities as to a gaseous composition as indicated herein or to a glass produced by this invention and thereby achieve a desired characteristic (as indicated herein) in such a glass. The quantity of such impurity or impurities (dopant or dopants) introduced into a given glass product (e.g., a glass layer in product glass composite) can very widely, depending upon a particular characteristic (e.g., index of refraction) desired, but generally falls in the range from about 0.1 to 30 weight percent (based on 100 weight percent total glass product weight), but larger and smaller amounts of any given dopant can be used if desired, as those skilled in the art will appreciate.
As used herein, the term "no significant tendency" in relation to doping elements employed in this invention has reference to the circumstance that such an element is not soluble in a product glass to an extent preferably not more than about 0.1 weight percent of a total product glass (in a layered form) based on a 100 weight percent total product glass weight.
Thus, for one presently preferred set of operating parameters, for each respective layer of glass deposited in a glass tube in accord with the present invention, the gas phase is passed through such tube at a flow rate of from about 200 to 2000 centimeters per minute. Concurrently, a longitudinally narrow oxyhydrogen gas burner is involved along the exterior of such tube in the direction of flow through such tube of such gas phase at a rate of from about 5 to 25 centimeters per minute, thereby to heat locally interior regions of such glass tube to a temperature ranging from about 1600 to 1900° C. over an axial (or longitudinal) moving zone of about 0.5 to 3·10 -3 grams per cubic centimeter. The total content of fluorine in such gas phase ranges from about 0.1 to 5 weight percent based upon 100 weight percent of the total such gase phase. Compositional progressive variations in glass forming components present in gas phases as needed to obtain a progressive radial change in profile of refractive induces from one layer to another are known generally to the prior art; see, for example, W. G. French; G. W. Tasker; J. R. Simpson: Graded index fiber waveguides with borosilicate composition: fabrication techniques. Applied Optics 15(1976) pp. 1803-1807.
To minimize the central refraction index disruption in a multilayered glass tube which can be, if desired, fabricated by prior art teachings as above cited, by the practice of this invention, one collapses such tube to form a rod in the presence of an etching gas in the inside of the tube. Preferably, the tube interior is flooded with such an etching gas during the collapsing. Preferably the tube containing at least two glass layers successively deposited on an outer tubular substrate.
Preferred etching gas compounds are those fluorine containing gaseous compounds hereinabove identified and which in addition to fluorine only contain elements which themselves, or whose oxides, have no significant tendency to dissolve in glass. A present particularly preferred such compound is sulfur hexafluoride.
The glass preforms manufactured in accord with the teachings of the present invention exhibit a central refractive index dip when the preform has been manufactured by means of collapsing a tube and when the core glass of such preform consists of at least two components, for examples, SiO 2 and GeO 2 . The glass components can evaporate away from the inside of the tube at the high temperature employed during the collapsing phase. Due to their usually different respective volatilities, this leads to a change of respective concentrations in the surface composition which is detectable after the collapse of the tube as a change of refractive index. In the case of a mixture such as SiO 2 -GeO 2 , this is then a refractive index dip because of the higher GeO 2 volatility and the effect of GeO 2 in increasing the refractive index. Since the evaporating materials are usually re-deposited at colder locations of the tube, refractive index peaks in the center of the preform can also be observed, these likewise having a disadvantageous effect on the band width of the fiber optical waveguides.
Fluorine compounds react with glass compositions. We are able to demonstrate that, given the standard conditions in the preform manufacturing process, a part of the glass volume is eroded form the inside wall of the tube, this typically corresponding to an 80% efficiency in the theoretical etching reaction:
1.5 SiO.sub.2 (solid)+SF.sub.6 (gas.)→1.5 SiF.sub.4 (gas.)+SO.sub.3 (gas.)
Thus, about 0.8 to 1.5 mol SiO 2 are eroded per mol SF 6 (see, in this regard, H. Schneider, U. Deserno, E. Lebetzki, A. Meier: "A new Method to Reduce the Central Dip and the OH Content in MCWD Preforms", Proc. Europ. Conference Optical Communication, Cannes, Sept. 1982, pp. 36-40, the disclosure and contents of which is entirely incorporated hereinto by reference. Similar reactions of the SF 6 also occur with the other glass components.
When, thus, gases containing fluorine are conducted through a tube during its collapse, then either the disrupted inner layer is eroded, or its formation is prevented by avoiding re-deposition. Product preforms thus exhibit a significantly narrower central range with a disrupted refractive index.
Preferably when so forming a rod from such a multilayered starting glass rod, the rod is prepared as described above using fluorine doping of individual glass layers.
In so processing a glass rod, the etching gas is preferably first passed through the starting rod at a gas flow rate of from about 200 to 2000 centimeters per minute while a narrow oxyhydrogen gas fumer is moved along the exterior of such glass tube in the direction of flow through such tube of such etching gas at a rate of from about 5 to 25 to heat locally interior regions of said glass tube to temperature ranging from about 1600 to 2000° C. over an axial (or longitudinal) moving zone of about 1 to 3 centimeters. The pressure of such gas phase ranges from about 0.5 to 3·10 -3 grams per cubic centimeter.
Thereafter, the so treated tube is flooded with etching gas while the burner is so moved again along the tube at such rate thereby to heat locally interior regions of such glass tube to a temperature about about 2000° C. and which temperature is at least sufficient to melt such glass tube into the desired rod. Excessive temperatures for melting are preferably avoided to minimize any unnecessary volatization of interior tube surface portions during rod formation.
Preferably the pressure of the etching gas ranges from about 0.5 to 3·10 -3 grams per cubic centimeter. Preferably, the etching gas is comprised of a mixture of 0.5 to 20% by volume of sulfur hexafluoride in oxygen. One preferred glass tube is comprised of SiO 2 and GeO 2 with fluorine doping.
EMBODIMENTS
The present invention is further illustrated by reference to the following examples. Those skilled in the art will appreciate that other and further embodiments are obvious and within the spirit and scope of this invention from the teachings of these present examples taken with the accompanying specification.
A silica glass tube approximately 1 m long and 20 mm in diameter with a wall thickness of 1.5 mm is heated in a glass lathe with the assistance of a narrow oxyhydrogen gas burner. First, the tube is cleaned. To that end, a gas stream consisting of 1100 NmL oxygen and 15 NmL/min sulfur hexafluoride is conducted through the tube (N thereby signifies the reference to normal conditions given one bar at 0° C.). The cleansing effect is brought about by the sulfur hexafluoride which has an etching influence on the glass at hot zone. The burner is moved in the direction of the gas stream along the tube with a speed of 15 cm/min and thereby drives the reaction products arising during the etching in front of it. The precipitation of glass layers which are intended for the jacket of the glass fiber is begun after three burner passes. To that end, 90 NmL/min silicon tetrachloride are added to the gas stream. The SF 6 feed can now be interrupted, but it can also be retained, although at a reduced value, for example 6 NmL/min. A precipitation of silica glass powder which is doped with fluorine then occurs in front of the burner and is clear-melted in the glass by means of the advancing burner.
After precipitation of ten such glass layers, the formation of jacket glass is terminated, and GeCl 4 gas, and if not already present, sulfur hexafluoride, preferably 6 NmL/min, are added to the gas stream, and the GeCl 4 gas stream is increased by approximately 44/60 NmL/min from burner pass to burner pass and, thus, from layer to layer.
It is expressly pointed out that the GeCl 4 gas stream is increased, but that the hexafluoride gas stream is kept constant.
After sixty layers have been precipitated in this manner, the formation of the core glass is terminated, the chloride feed is interrupted, and the flow of sulfur hexafluoride is reduced to approximately 1.5 NmL/min, and the flow of oxygen to 300 NmL/min, and the burner speed is reduced, so that the tube temperature rises to approximately 2000° C. At this temperature, the tube begins to collapse. Thereby due to the slight flow of sulfur hexafluoride, a slight etching and, thus, cleaning of the inside wall of the tube occurs.
Then, after approximately five burner passes, the gas flow-through is completely stopped, and the capillary tube which arises is melted into a solid rod in a new burner pass.
The rod or preform generated in such manner exhibits an outside diameter of 11 mm. The diameter of the core amounts to 5.2 mm. In the core, the germanium concentration increases radially from the outside toward the inside from 0 to 12 wt. %. The concentration curve closely follows a paraboloid as envelope. The fluoride concentration in all deposited layers is uniform at approximately 0.6% by weight of fluorine. With a half-width value of only 60 μm, the GeO 2 concentration sink in the center of the core is extremely narrow. This is essentially achieved due to the cleansing effect caused by the sulfur hexafluoride flow during the collapsing operation. The rinsing of the glass wall with sulfur hexafluoride after that also leads to a cleansing effect which has an extremely favorably influence on the glass being manufactured.
Given test conditions which were otherwise the same, but however, without a fluorine additive to the gaseous phase, a GeO 2 profile exhibits pronounced peaks and a broad concentration sink in the center of the core. Fluctuations between peaks and sinks of approximately 15% were observed. Pulse widths of approximately 2 ns were observed at two kilometer long fiber drawn from such a preform with pronounced peaks. In contrast therto, a pulse spread of only 0.5 ns, which corresponds to a band width of 2 GH z /km, was observed in an equivalent fiber with a fluoride additive. Typical attenuation values of the fibers doped with fluorine are 0.8 dB/km at 1.55 mm. 5.5 dB/km (water maximum) were measured at 1.39 μm. The water maximum is higher without fluorine additive (50 kB/km).
Thus, in one aspect, the present invention is directed to an improved method for making a solid glass rod from which glass fibers having a refractive index profile having a uniform paraboloid configuration for use as light waveguides in optical communicators technology are formable. This method utilizes a series of sequential steps. Thus one heats an alkali-free silica glass tube which has been initially interiorly cleaned by a gas stream comprised of oxygen and sulfur hexafluoride using a narrow oxyhydrogen gas burner. Simultaneously, one first passes at a mean linear flow rate of from about 200 to 2000 centimeters per minute through said tube a first gaseous composition comprised of silicon tetrachloride, oxygen, and at least one fluorine containing gaseous compound. Such heating is conducted by moving the burner along the exterior of the tube in the direction of gas flow through the tube at a burner moving rate of from about 5 to 25 centimeters per minute. The interrelationship between such heating, such moving, such first passing, and such first gaseous composition is such that in front of the zone of heating produced by said burner a precipitation of silica glass powder doped with fluorine occurs which powder is clear-melted onto the interior wall portions of said tube in such zone of heating. This step involves at least two such first passings along the tube.
Next, a second passing at a mean linear flow rate of from about 200 to 2000 centimeters per minute through said tube is carried out using a second gaseous composition. As before, the fluorine is in the initial form of at least one fluorine containing gaseous compound. This second gaseous composition further includes silicon tetrachloride, at least one chloride of the further elements Ge, Al, Ti, Ta, Sn, Nb, Zr, Yb, La, P, B, Sb, and oxygen. Such second repeated passing is with such heating and such moving at least once. With each said moving, a new layer of glass is formed on said interior wall portions.
Next, a third passing at a mean linear flow rate of from about 200 to 200 centimeters per minute through said tube is undertaken using a final gaseous composition comprised of sulfur hexafluoride and oxygen. Concurrently, such moving is continued at a moving rate of from about 2 to 15 centimeters per minute. The interrelationship between such heating, such moving, such third passing, and such final gaseous composition being such that a cleaning of said interior wall portions results. Such third passing is repeated at least once.
Finally, one moves such burner along the resulting tube which maintains a temperature sufficient to melt such resulting tube into a solid rod.
Glass rods which are produced by the foregoing method are products of this invention.
EXAMPLE 2
In a second aspect, the present invention is directed to an improved method of making a solid glass rod with an arbitrary refractive index profile (step like or parabolic or otherwise) having only a small central refractive index disturbance. In this case, e.g., one may perform the same sequential steps as given in the example 1 but with or without addition of SF 6 during the first cleansing of the tube, the jacket glass deposition and/or the core glass deposition. After interruption of the chloride feed, the flow of 1.5 NmL/min. SF 6 and 300 NmL/min. O 2 are adjusted through the tube and the burner speed is reduced, so that the tube temperature rises to approximately 2000° C. At this temperature, the tube begins to shrink. After four or five burner passes, the gas flow-through is completely stopped and the capillary is closed.
It is also possible to use higher SF 6 flow tubes, e.g., 15 NmL/min. To avoid high mass losses by etching from the inside tube wall, it is preferable, but not necessary, to use the SF 6 flow only during one pass, preferably the fourth or fifth of the otherwise identical collapory procedure.
In both cases, one obtains a GeO 2 profile with an extremely narrow GeO 2 dip in the central region of approximately 50 μm diameter at half depth. After drawing the 125 μm diameter from the rod this dip is not resolveable as a profile defect. With the low SF 6 flow rate during collapsing, F doping of the inside tube wall occurs by diffusion which leads to a broad F peak in the center of typ. 0.8% by weight of fluorine in the glass, whereas with high SF 6 flow rate, the F doping is lower by a factor of five. In the first case, the corresponding refractive index profile shows a broad refractive index dip in fluorine diminishes the refractive index n of the glass (Δn about 0.0015), which is also observed in the fiber. In the second case, the n profile is almost flat (deviations smaller than 0.0005). For details see H. Schneider et al., publ. cit. p. 11). Bh changing the fluoride flow and/or the type of fluoride in the tube during collapse, the refractive index in the central region can be modified in a certain range which is at the present time not fully explored.
EXAMPLE 3
It is also possible to use the fluoride doping of the gas phase only during glass precipitation. In this case, one may get an arbitrary GeO 2 concentration profile depending on the arbitrary chosen GeCl 4 gas phase concentration program (e.g., step-like or parabolic or otherwise defined), but smooth and without the ripples of the individual layers.
EXAMPLE 4
Before our invention of the use of SF 6 , we developed the same procedure as described in example 1, but without the use of SF 6 . These conditions, which we found by experience, might be similar to gas flow ranges sometimes quoted in the literature, but most likely they are not identical with specific and mostly not retrailed conditions used by others. The reason for this might be seen in the difference in experimental details as e.g., tube sizes and quality, type of burner used, temperature profile of the burner, type of temperature measurement or different target dimensions and concentrations.
Under these conditions without SF 6 throughout the process, one obtains a rod of nearly the same dimensions as in example 1 but with a GeO 2 concentration profile which exhibits pronounced ripples superimposed on the near parabolic profile and a broad (200 μm diameter at half depth) central profile dip.
In conclusion, let it be pointed out that the present invention can be advantageously employed everywhere where a desired refractive index or refractive index profile is to be produced by means of precipitating a multitude of glass layers. | 4y
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of and claims benefit of the filing date of U.S. application Ser. No. 12/776,306, filed May 7, 2010, entitled “PATTERNED HEAT MANAGEMENT MATERIAL,” which claims benefit of the filing date of U.S. Provisional Application No. 61/176,448, filed May 7, 2009, entitled “HEAT REFLECTIVE MATERIAL,” the disclosures of which are incorporated herein in their entirety. U.S. application Ser. No. 12/776,306 is also a continuation-in-part of and claims the benefit of the filing date of U.S. Design Patent applications 29/336,730, filed on May 7, 2009; 29/360,364, filed on Apr. 23, 2010; 29/346,787, filed on Nov. 5, 2009; 29/346,784, filed on Nov. 5, 2009; 29/346,788, filed on Nov. 5, 2009; 29/346,785, filed on Nov. 5, 2009; and 29/346,786, filed on Nov. 5, 2009; the disclosures of which are incorporated herein in their entirety.
TECHNICAL FIELD
Embodiments of the present disclosure relate generally to a fabric or other material used for body gear and other goods having designed performance characteristics, and in particular to methods and apparatuses that utilize a pattern of heat managing/directing elements coupled to a base fabric to manage heat through reflection or conductivity while maintaining the desired properties of the base fabric.
BACKGROUND
Currently, heat reflective materials such as aluminum and mylar typically take the form of a unitary solid film that is glued or otherwise attached to the interior of a garment, such as a jacket. The purpose of this layer is to inhibit thermal radiation by reflecting the body heat of the wearer and thereby keeping the garment wearer warm in colder conditions. However, these heat reflective linings do not transfer moisture vapor or allow air passage, thus they trap moisture near the body. Because the application of a heat reflective material impedes the breathability and other functions of the underlying base fabric, use of heat reflective materials during physical activity causes the inside of a garment to become wet, thereby causing discomfort and accelerating heat loss due to the increased heat conductivity inherent in wet materials. Further, these heat reflective coated materials impair the ability of the material to stretch, drape, or hang in a desired fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings. Embodiments of the invention are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings.
FIGS. 1A illustrates an upper body garment such as a coat having a lining of base material with heat directing/management elements disposed thereon, in accordance with various embodiments;
FIGS. 1B-1E illustrate various views of examples of patterned heat directing/management elements disposed on a base fabric or material, in accordance with various embodiments;
FIGS. 2A and 2B illustrate examples of patterned heat directing/management elements disposed on a base fabric, in accordance with various embodiments;
FIGS. 3A-3E illustrate examples of patterned heat directing/management elements disposed on a base fabric, in accordance with various embodiments;
FIG. 4 illustrates an upper body garment such as a coat having a lining of base material with heat directing/management elements disposed thereon, in accordance with various embodiments;
FIG. 5 illustrates an upper body garment such as a coat having a lining of base material with heat directing/management elements disposed thereon, in accordance with various embodiments;
FIG. 6 illustrates an upper body garment such as a coat having a lining of base material with heat directing/management elements disposed thereon, in accordance with various embodiments;
FIG. 7 illustrates an upper body garment such as a coat having a lining of base material with heat directing/management elements disposed thereon, in accordance with various embodiments;
FIGS. 8A-D illustrate various views of a patterned heat management material as used in a jacket, in accordance with various embodiments;
FIG. 9 illustrates an example of a patterned heat management material as used in a boot, in accordance with various embodiments;
FIG. 10 illustrates an example of a patterned heat management material as used in a glove, where the cuff is rolled outward to show the lining, in accordance with various embodiments;
FIG. 11 illustrates an example of a patterned heat management material as used in a hat, in accordance with various embodiments;
FIG. 12 illustrates an example of a patterned heat management material as used in a pair of pants, in accordance with various embodiments;
FIG. 13 illustrates an example of a patterned heat management material as used in a sock, in accordance with various embodiments;
FIG. 14 illustrates an example of a patterned heat management material as used in a boot, in accordance with various embodiments; and
FIGS. 15A and B illustrate two views of a patterned heat management material as used in a reversible rain fly ( FIG. 15A ) and as a portion of a tent body ( FIG. 15B ), in accordance with various embodiments.
DETAILED DESCRIPTION OF EMBODIMENTS
In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which are shown by way of illustration embodiments in which the disclosure may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scopes of embodiments, in accordance with the present disclosure, are defined by the appended claims and their equivalents.
Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments of the present invention; however, the order of description should not be construed to imply that these operations are order dependent.
The description may use perspective-based descriptions such as up/down, back/front, and top/bottom. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of embodiments of the present invention.
The terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical or electrical contact with each other. “Coupled” may mean that two or more elements are in direct physical or electrical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.
For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” means (A), (B), or (A and B). For the purposes of the description, a phrase in the form “at least one of A, B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C). For the purposes of the description, a phrase in the form “(A)B” means (B) or (AB) that is, A is an optional element.
The description may use the phrases “in an embodiment,” or “in embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present invention, are synonymous.
In various embodiments a material for body gear is disclosed that may use a pattern of heat management material elements coupled to a base fabric to manage, for example, body heat by directing the heat towards or away from the body as desired, while still maintaining the desired transfer properties of the base fabric. For example, referring to FIGS. 1B-1E , in one embodiment, a plurality of heat management or heat directing elements 10 may be disposed on a base fabric 20 in a generally non-continuous array, whereby some of the base fabric is exposed between adjacent heat management elements. The heat directing function of the heat management elements may be generally towards the body through reflectivity or away from the body through conduction and/or radiation or other heat transfer property.
The heat management elements 10 may cover a sufficient surface area of the base fabric 20 to generate the desired degree of heat management (e.g. heat reflection toward the body to enhance warmth, or heat conductance away from the body to help induce cooling). A sufficient area of base fabric may be exposed to provide the desired base fabric function (e.g., stretch, drape, breathability, moisture vapor or air permeability, or wicking).
In accordance with various embodiments, the base fabric may be a part of any form of body gear, such as bodywear (see e.g. FIGS. 1 A and 4 - 13 ), sleeping bags (see e.g. FIG. 14 ), blankets, tents (see e.g. FIG. 15B ), rain flys (see e.g. FIG. 15A ) etc. Bodywear, as used herein, is defined to include anything worn on the body, including, but not limited to, outerwear such as jackets, pants, scarves, shirts, hats, gloves, mittens, and the like, footwear such as shoes, boots, slippers, and the like, sleepwear, such as pajamas, nightgowns, and robes, and undergarments such as underwear, thermal underwear, socks, hosiery, and the like.
In various embodiments, single-layer body gear may be used and may be comprised of a single layer of the base fabric, whereas other embodiments may use multiple layers of fabric, including one or more layers of the base fabric, coupled to one or more other layers. For instance, the base fabric may be used as a fabric lining for body gear.
In various embodiments, the array of heat management elements may be disposed on a base fabric having one or more desired properties. For example, the underlying base material may have properties such as air permeability, moisture vapor transfer and/or wickability, which is a common need for body gear used in both indoor and outdoor applications. In other embodiments, the separations between heat management elements help allow the base material to have a desired drape, look, and/or texture. In some embodiments, the separations between heat management elements my help allow the base material to stretch. Suitable base fabrics may include nylon, polyester, rayon, cotton, spandex, wool, silk, or a blend thereof, or any other material having a desired look, feel, weight, thickness, weave, texture, or other desired property. In various embodiments, allowing a designated percentage of the base fabric to remain uncovered by the heat management material elements may allow that portion of the base fabric to perform the desired functions, while leaving enough heat management material element surface area to direct body heat in a desired direction, for instance away from or toward the body of a user.
For example, the heat management elements may be positioned in such a way and be made of a material that is conducive for directing heat generated by the body. In one embodiment, the heat management elements may be configured to reflect the user's body heat toward the user's body, which may be particularly suitable in cold environments. In another embodiment, the heat management elements may be configured to conduct the user's body heat away from the user's body, which may be particularly suitable in warmer environments.
In various embodiments, the base fabric may include heat management elements disposed on an innermost surface of the body gear such that the elements are disposed to face the user's body and thus are in a position to manage body heat, as discussed above (e.g. reflect heat or conduct heat). In some other embodiments, the heat management elements may be disposed on the exterior surface of the body gear and/or base fabric such that they are exposed to the environment, which may allow the heat management elements, for example, to reflect heat away from the user, while allowing the base fabric to adequately perform the desired functions. In some embodiments, the heat management elements may perform these functions without adversely affecting the stretch, drape, feel, or other properties of the base fabric.
In some embodiments, the heat management elements may be an aluminum-based material (particularly suited for reflectivity), copper based material (particularly suited for conductivity) or another metal or metal alloy-based material. Non-metallic or alloy based materials may be used as heat directing materials in some embodiments, such as metallic plastic, mylar, or other man-made materials, provided that they have heat reflective or conductive properties.
In various embodiments, the heat management elements may be permanently coupled to the base fabric in a variety of ways, including, but not limited to gluing, heat pressing, printing, or stitching. In some embodiments, the heat management elements may be coupled to the base fabric by frequency welding, such as by radio or ultrasonic welding.
In various embodiments, the heat directing properties of the heat management elements may be influenced by the composition of the base fabric or the overall construction of the body gear. For example, a base fabric may be used that has significant insulating properties. When paired with heat management elements that have heat reflective properties, the insulative backing/lining may help limit any conductivity that may naturally occur and enhance the reflective properties of the heat management elements. In another example, the base fabric may provide little or no insulative properties, but may be coupled to an insulating layer disposed on the side of the base fabric opposite the heat directing material elements. The separate insulation layer may help reduce the potential for heat conductivity of the elements and enhance their reflectivity. In some embodiments, the heat management elements may become more conductive as the air layer between the garment and the wearer becomes more warm and humid. Such examples may be suitable for use in cold weather applications, for instance.
In various embodiments, a base fabric may be used that has little or no insulative properties. When paired with heat directing elements that are primarily configured to conduct heat, as opposed to reflecting heat, the base fabric and heat-directing elements may aid in removing excess body heat generated in warmer climates or when engaging in extreme physical activity. Such embodiments may be suitable for warm weather conditions.
In various embodiments, the heat management material elements may be applied in a pattern or a continuous or discontinuous array defined by the manufacturer. For example, as illustrated in FIGS. 1A-1E , heat management material elements 10 , may be a series of dot-like heat reflective (or heat conductive) elements adhered or otherwise secured to the base fabric 20 in a desired pattern. Such a configuration has been found to provide heat reflectivity and thus warmth to the user (e.g., when heat reflective elements are used), or, in the alternative, heat conduction and thus cooling to the user (e.g., when heat conductive elements are used), while still allowing the base fabric to perform the function of the desired one or more properties (e.g. breathe and allow moisture vapor to escape through the fabric in order to reduce the level of moisture build up).
Although the illustrated embodiments show the heat management material elements as discrete elements, in some embodiments, some or all of the heat management material elements may be arranged such that they are in connection with one another, such as a lattice pattern or any other pattern that permits partial coverage of the base fabric.
In various embodiments, the configuration or pattern of the heat management elements themselves may be selected by the user and may take any one of a variety of forms. For example, as illustrated in FIGS. 2A-2B , 3 A- 3 E, and 4 - 6 , the configuration of the heat management elements 10 disposed on a base fabric 20 used for body gear may be in the form of a variety of geometrical patterns (e.g. lines, waves, triangles, squares, logos, words, etc.)
In various embodiments, the pattern of heat management elements may be symmetric, ordered, random, and/or asymmetrical. Further, as discussed below, the pattern of heat management elements may be disposed on the base material at strategic locations to improve the performance of the body wear. In various embodiments, the size of the heat management elements may also be varied to balance the need for enhanced heat directing properties and preserve the functionality of the base fabric.
In embodiments, the density or ratio of the surface area covered by the heat management material elements to the surface are of base fabric left uncovered by the heat management material elements may be from about 3:7 (30%) to about 7:3 (70%). This range has been shown to provide a good balance of heat management properties (e.g., reflectivity or conductivity) with the desired properties of the base fabric (e.g., breathability or wicking, for instance). In particular embodiments, this ratio may be from about 4:6 (40%) to about 6:4 (60%).
In various embodiments, the placement, pattern, and/or coverage ratio of the heat management elements may vary. For example the heat management elements may be concentrated in certain areas where heat management may be more critical (e.g. the body core) and non existent or extremely limited in other areas where the function of the base fabric property is more critical (e.g. area under the arms or portions of the back for wicking moisture away from the body). In various embodiments, different areas of the body gear may have different coverage ratios, e.g. 70% at the chest and 30% at the limbs, in order to help optimize, for example, the need for warmth and breathability.
In various embodiments, the size of the heat management elements may be largest (or the spacing between them may be the smallest) in the core regions of the body for enhanced reflection or conduction in those areas, and the size of the heat management elements may be the smallest (or the spacing between them may be the largest) in peripheral areas of the body. In some embodiments, the degree of coverage by the heat management elements may vary in a gradual fashion over the entire garments as needed for regional heat management. Some embodiments may employ heat reflective elements in some areas and heat conductive elements in other areas of the garment.
In various embodiments, the heat management elements may be configured to help resist moisture buildup on the heat management elements themselves and further enhance the function of the base fabric (e.g. breathability or moisture wicking). In one embodiment, it has been found that reducing the area of individual elements, but increasing the density may provide a better balance between heat direction (e.g. reflectivity or conductivity) and base fabric functionality, as there will be a reduced tendency for moisture to build up on the heat management elements. In some embodiments, it has been found that keeping the surface area of the individual heat management elements below 1 cm 2 can help to reduce the potential for moisture build up. In various embodiments, the heat management elements may have a maximum dimension (diameter, hypotenuse, length, width, etc.) that is less than or equal to about 1 cm. In some embodiments, the maximum dimension may be between 1-4 mm. In other embodiments, the largest dimension of a heat management element may be as small as 1 mm, or even smaller.
In some embodiments, the topographic profile of the individual heat management elements can be such that moisture is not inclined to adhere to the heat management element. For example, the heat management element may be convex, conical, fluted, or otherwise protruded, which may help urge moisture to flow towards the base fabric. In some embodiments, the surface of the heat management elements may be treated with a compound that may help resist the build up of moisture vapor onto the elements and better direct the moisture to the base fabric without materially impacting the thermal directing property of the elements. One such example treatment may be a hydrophobic fluorocarbon, which may be applied to the elements via lamination, spray deposition, or in a chemical bath.
In various embodiments, the heat management elements may be removable from the base fabric and reconfigurable if desired using a variety of releasable coupling fasteners such as zippers, snaps, buttons, hook and loop type fasteners (e.g. Velcro), and other detachable interfaces. Further, the base material may be formed as a separate item of body gear and used in conjunction with other body gear to improve thermal management of a user's body heat. For example, an upper body under wear garment may be composed with heat management elements in accordance with various embodiments. This under wear garment may be worn by a user alone, in which case conduction of body heat away from the user's body may typically occur, or in conjunction with an insulated outer garment which may enhance the heat reflectivity of the user's body heat.
In various embodiments, the heat management elements may be applied to the base fabric such that it is depressed, concave, or recessed relative to the base fabric, such that the surface of the heat management element is disposed below the surface of the base fabric. This configuration may have the effect of improving, for example, moisture wicking, as the base fabric is the portion of the body gear or body gear lining that engages the user's skin or underlying clothing. Further, such contact with the base fabric may also enhance the comfort to the wearer of the body gear in applications where the skin is in direct contact with the base fabric (e.g. gloves, mittens, underwear, or socks).
FIGS. 8-15 illustrate various views of a patterned heat management fabric used in a variety of body gear applications, such as a jacket ( FIGS. 8A-D ), boot ( FIG. 9 ), glove ( FIG. 10 ), hat ( FIG. 11 ), pants ( FIG. 12 ), sock ( FIG. 13 ), sleeping bag ( FIG. 14 ), tent rain fly ( FIG. 15A ) and tent ( FIG. 15B ). Each of the body gear pieces illustrated include a base material 20 having a plurality of heat management elements 10 disposed thereon.
While the principle embodiments described herein include heat management elements that are disposed on the inner surface of the base fabric, in various embodiments, the heat management material elements may be used on the outside of body gear, for instance to reflect or direct heat exposed to the outside surface of the gear. For instance, in some embodiments, base fabric and heat reflective elements, such as those illustrated in FIGS. 1B-3E , may be applied to an outer or exterior surface of the body gear, such as a coat, sleeping bag, tent or tent rain fly, etc in order to reflect heat away from the user.
In some embodiments, the body gear may be reversible, such that a user may determine whether to use the fabric to direct heat toward the body or away from the body. An example of such reversible body gear is illustrated in FIG. 15A . In this embodiment, the heat management elements may be included on one side of a tent rain fly. In one embodiment, the rain fly may be used with the heat management elements facing outward, for example in hot weather or sunny conditions, in order to reflect heat away from the body of the tent user. Conversely, in cold weather conditions, for example, the tent rain fly may be reversed and installed with the heat management elements facing inward, toward the body of a user, so as to reflect body heat back toward the tent interior. Although a tent rain fly is used to illustrate this principle, one of skill in the art will appreciate that the same concept may be applied to other body gear, such as reversible jackets, coats, hats, and the like. FIG. 15B illustrates an example wherein at least a portion of the tent body includes a fabric having a plurality of heat management elements disposed thereon. In the illustrated embodiment, the heat reflective elements are facing outward and may be configured to reflect heat away from the tent and thus away from the body of the tent user. In other embodiments, the elements may be configured to face inward.
Although certain embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent embodiments or implementations calculated to achieve the same purposes may be substituted for the embodiments shown and described without departing from the scope of the present invention. Those with skill in the art will readily appreciate that embodiments in accordance with the present invention may be implemented in a very wide variety of ways. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that embodiments in accordance with the present invention be limited only by the claims and the equivalents thereof. | 4y
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RELATED APPLICATION
[0001] This application claims priority under 35 USC §119 to Provisional Patent Application No. 60/477,730 filed on Jun. 10, 2003, entitled “Glucose Measuring Device For Use In Personal Area Network”, the disclosure of which is incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
[0002] This invention relates to a device and method for determining and reporting glucose readings in wireless personal area networks for diabetics.
BACKGROUND
[0003] The number of diagnosed cases of diabetes continues to increase in the U.S. and throughout the world, creating enormous economic and public health consequences. Devices and therapies that improve the quality of life for the diabetic patient thus are important not only for the patient, but for society at large. One area in which recently developed technologies have been able to improve the standard of care has been in the maintenance of tight control over the blood glucose levels. It is well known that if a diabetic patient's blood glucose values can be maintained in a relatively narrow and normal range of from about 80 milligrams per deciliter (mg/dL) to about 120 mg/dL, the physiologically damaging consequences of unchecked diabetes can be minimized. With better blood glucose information, diabetic patients can better exercise tight control of their blood glucose level through a variety of means, including diet, exercise, and medication. For this reason a large industry has developed to provide the diabetic population with ever more convenient and accurate ways to measure blood glucose. There are many forms of these measuring devices; one common type is represented by hand-held electronic meters which receive blood samples via enzyme-based “test strips”. In using these systems, the patient lances a finger or alternate body site to obtain a blood sample, the strip is inserted into a test strip opening in the meter housing, the sample is applied to the test strip and the electronics in the meter convert a current generated by the enzymatic reaction in the test strip to a blood glucose value. The result is displayed on the (typically) liquid crystal display of the meter. Usually, this display must be large so that diabetics who often have deteriorating vision, can more easily see the result.
[0004] It is known that such hand-held meters can advantageously be manufactured to include wireless communication capability. Such capability can assist the user in downloading data to a home computer or to a handheld computing device, for example. This minimizes the need for the user to write down data and transfer it later to an electronic record.
[0005] It is also known that hand-held meters are often given to users, so that suppliers of the strips used with the meters can generate greater strip sales. This makes the cost of the hand-held meters critical to profitability of the manufacturers. If the cost of a meter is relatively high, profits from the sale of strips will be small or worse yet, non-existent. If the cost of the meter can be reduced, profitability is improved.
[0006] Lastly, it is well known that if a strip and meter system is convenient to use, patients will test more often and compliance with treatment programs will improve. Including wireless communication in the meter adds convenience, but at a cost. For these reasons, there is a continuing need for a low cost meter and strip glucose monitoring system that nevertheless has highly convenient features, including wireless communication capabilities.
SUMMARY OF THE INVENTION
[0007] The present invention is a glucose monitoring system which includes a glucose meter system of the meter and strip type that includes wireless communication capabilities. The system can be a reduced cost system however, by eliminating components from the meter, such as the relatively large LCD display, and instead relying on such components in other electronic devices that now typically surround a patient almost every day and can form part of the monitoring system. By eliminating high cost components from the meter but retaining the wireless communication functionality, the meter portion of the system can be relatively low cost, yet the system overall provides highly convenient features to the user.
[0008] Accordingly, in one embodiment of the present invention, there is provided a data communication system including a data network, a client unit operatively coupled to the data network, and a server unit operatively coupled to the data network for communicating with the client unit, said server unit further configured to receive blood glucose related data from the client unit over the data network.
[0009] The client unit may be configured to encrypt the blood glucose related data for wireless transmission over the data network to the server unit. Moreover, the client unit may include a blood glucose meter.
[0010] In an alternate embodiment, the data communication over the data network may include one of a 802.11 protocol, a Bluetooth protocol, an RF protocol, and an IRDA protocol.
[0011] Furthermore, the server unit may in one embodiment include a display.
[0012] The system in accordance with yet another embodiment may include a base unit configured to communicate with the server unit over the data network, the base unit configured to store data received from the server unit, and further, the base unit configured to provide an insulin pump protocol to said server unit.
[0013] The data network may include a personal area network, where the personal area network is configured for short range wireless communication.
[0014] In a further embodiment, the client unit may be configured with password protection.
[0015] Additionally, the client unit may include one or more of a compact handheld device, a personal digital assistant, and a mobile telephone.
[0016] In accordance with another embodiment of the present invention, there is provided a method of providing a data communication system including the steps of establishing a data network, operatively coupling a client unit to the data network, and operatively coupling a server unit to the data network to communicate with the client unit, the server unit further configured to receive blood glucose related data from the client unit over the data network.
[0017] The method may further include the step of encrypting the blood glucose related data for wireless transmission over the data network.
[0018] Moreover, the step of establishing the data network may include the step of implementing one of a 802.11 protocol, a Bluetooth protocol, an RF protocol, and an IrDA protocol.
[0019] Also, the method in a further embodiment may include the step of displaying the data received from the client unit.
[0020] Moreover, in another embodiment, the method may include the step of configuring a base unit to communicate with the server unit over the data network, the step further including storing data received from the server unit. Also, the step of configuring the base unit further may include the step of providing an insulin pump protocol to said server unit. Moreover, the method may also include configuring the personal area network for short range wireless communication.
[0021] Additionally, the method may include the step of password protecting access to the client unit.
[0022] In accordance with yet another embodiment of the present invention, there is provided a personal area network, a blood glucose meter operatively coupled to the personal area network, and a server unit operatively coupled to the personal area network for wirelessly communicating with the meter, said server unit further configured to receive blood glucose data from the meter over the personal area network.
[0023] The invention will now be described by reference to the figures, wherein like reference numerals and names indicate corresponding structure throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a schematic view showing typical data signal flow between devices of a wireless system constructed according to one embodiment of the present invention.
[0025] FIG. 2 is a schematic view showing the client device of FIG. 1 .
[0026] FIG. 3 is a schematic view showing the server device of FIG. 1 .
[0027] FIG. 4 is a pictoral view showing a typical client device and typical server devices.
[0028] FIG. 5 is a perspective view showing an integrated device of an alternative embodiment.
DETAILED DESCRIPTION
[0029] Referring to FIG. 1 , a wireless system constructed according to a preferred embodiment of the present invention will be described. Test strip 101 electrically communicates with client device 102 , which wirelessly communicates with server device 104 , such as by two-way radio frequency (RF) contact, infrared (IR) contact, Bluetooth contact or other known wireless means 103 . Optionally, server device 104 can also communicate with other devices such as data processing terminal 105 by direct electronic contact, via RF, IR, Bluetooth or other wireless means.
[0030] Test strip 101 is a commonly known electrochemical analyte test strip, such as a blood glucose test strip as described in U.S. patent application Ser. No. 09/434,026 filed Nov. 4, 1999 entitled “Small Volume In Vitro Analyte Sensor and Methods”, incorporated herein by reference. It is mechanically received in a test strip port of a client device 102 , similar to a commonly known hand-held blood glucose meter as described in the aforementioned patent application. In the preferred embodiment, client device 102 is constructed without a user interface or display to keep the size and cost of device 102 to a minimum. Client device 102 can take the form of a highlighter or easel-sized pen, as shown in FIG. 4 , and can be powered by a single AA or AAA size battery.
[0031] Client device 102 wirelessly communicates with server device 104 , preferably using a common standard such as 802.11 or Bluetooth RF protocol, or an IrDA infrared protocol. Server device 104 can be another portable device, such as a Personal Digital Assistant (PDA) or notebook computer, or a larger device such as a desktop computer, appliance, etc. as shown by the examples in FIG. 4 . Preferably, server device 104 does have a display, such as a liquid crystal display (LCD), as well as an input device, such as buttons, a keyboard, mouse or touch-screen. With this arrangement, the user can control client device 102 indirectly by interacting with the user interface(s) of server device 104 , which in turn interacts with client device 102 across wireless link 103 .
[0032] Server device 104 can also communicate with another device 105 , such as for sending glucose data from devices 102 and 104 to data storage in device 105 , and/or receiving instructions or an insulin pump protocol from a health care provider computer 105 . Examples of such communication include a PDA 104 synching data with a personal computer (PC) 105 , a mobile phone 104 communicating over a cellular network with a computer 105 at the other end, or a household appliance 104 communicating with a computer system 105 at a physician's office.
[0033] Referring to FIG. 2 , internal components of a blood glucose meter 102 of the preferred embodiment are shown. Alternatively, user input 202 , such as push button(s), and other sections can be eliminated to reduce size and cost of client device 102 . The glucose meter housing may contain any glucose sensing system of the type well known in the art that can be configured to fit into a small profile. Such a system can include, for example, the electrochemical glucose strip and meter sensing system sold by TheraSense, Inc. of Alameda, Calif. under the FreeStyle® brand, or other strip and meter glucose measuring systems. The housing may thus encompass the sensor electronics and a strip connector, which connector is accessed via a test strip port opening in the housing. The housing will typically also include a battery or batteries.
[0034] Referring to FIG. 3 , internal components of a server device 104 of the preferred embodiment are shown. Note that a redundant test strip interface 301 can be provided if desired for receiving test strips 101 . Device 104 can be a proprietary unit designed specifically for use with blood glucose meters, or can be a generic, multipurpose device such as a standard PDA. An example of a similar device designed for blood glucose testing is disclosed in U.S. Pat. No. 6,560,471 issued May 6, 2003 to TheraSense, Inc. entitled “Analyte Monitoring Device and Methods of Use”, incorporated herein by reference.
[0035] FIG. 4 shows examples of the devices to and from which the meter of the invention can communicate. Such devices will become part of an individual's personal area network and each becomes enabled with short range wireless communication capabilities. Desktop, laptop and handheld computers, as well as printers can be so enabled and will provide displays and printouts valuable as records for the diabetic. Telephones will also be enabled in this fashion and can be used for displaying glucose data as well as further transmitting the data over larger networks. Many of these devices can assist the diabetic by responding to glucose levels by providing alarms, or suggesting that action be taken to correct a hypo or hyperglycemic condition, or to call necessary medical assistance. Diabetics are aware of the risks involved in driving when glucose levels are out of range and particularly when they are too low. Thus, the navigation computer in the diabetic's car may become part of the local area network and will download glucose data from the meter when the diabetic enters the car. For safety sake, the car computer system may be programmed to require that the diabetic perform a glucose test before driving, and more specifically the car may be disabled unless the diabetic takes the test and the result is in an appropriate range.
[0036] The pen shaped client device 102 shown in FIG. 4 preferably has a test strip port 201 (not shown in FIG. 4 ) located on its distal end. Because the sensitive analog “front end” circuitry associated with measuring the very small electrochemistry currents from test strips 101 is located adjacent strip port 201 , it is advisable to not design a wireless link antenna too close to this distal end as it may interfere with the proper operation of the glucose sensing circuitry. On the other hand, if the wireless link antenna is located at the proximal end of the client device 102 , it will likely be covered by the hand of the user holding it, which may limit the range of the low transmission power device to an unacceptable distance. Accordingly, it is preferable to design the layout of client device 102 such that an internal antenna is located in a middle section of the device away from the distal and proximal ends.
[0037] Referring to FIG. 5 , an alternative embodiment of the present invention is shown. Due to the reduced size of a blood glucose meter 102 when it does not include a display or push buttons, it can be combined with a lancing device to form an integrated unit 102 ′. Test strip port 201 can be located in the side of integrated device 102 ′ or wherever there is room available. A test strip storage compartment can also be located within integrated device 102 ′ and accessed through a flip-lid 220 or other suitable closure means. If room permits, a second test strip storage compartment (not shown) can be included so that fresh strips and used strips can be separately stored. Preferably, a desiccant is provided in one of the storage compartments to preserve the fresh strips. The design and use of lancing devices is described in U.S. Pat. No. 6,283,982 issued to TheraSense, Inc. on Sep. 4, 2001 entitled “Lancing Device and Method of Sample Collection”, incorporated herein by reference. By integrating these features together in a single device without a user interface, the typical test kit that is carried around by people with diabetes can be made much smaller, easier to handle, and less costly.
[0038] Thus, one of the important features of the invention is reliance of the “displayless” glucose meter unit on a separate display device in order to minimize the complexity and cost of the meter unit. This permits the user to use the larger display units within his or her personal area network, all of which can be synchronized as they interact and communicate with the wireless enabled meter. When the meter is used, the sequences through which the user must “step” to complete the test are readily viewed on the larger display units (e.g. entering the calibration code, prompting application of the sample). At the same time the meter unit is simplified, smaller and less expensive to manufacture. Additionally, control buttons that are found on typical glucose meters can be eliminated, saving additional size and cost, since the user can rely on the user in out features of the server device instead. It is expected that the simplified, wireless enabled meters of the invention may ultimately become inexpensive enough to make them disposable after a specified number of uses, permitting the producer to routinely upgrade as appropriate.
[0039] Additionally, the system permits the user to include security coding at any time the meter unit accesses a display device, so that the user's data is secure. That is, it is considered an important feature of the invention that when the “client” meter of the invention is used, that the system will require the user to enter an identity code in order to verify that the person handling the meter is indeed an authorized user. Of course, it is possible for the system to permit more than one user if the meter owner so desires. Moreover, the user's data may optionally be encrypted prior to wireless transmission and thereafter respectively decrypted upon wireless reception.
[0040] While the module need not include a large or expensive display, it may nevertheless be advantageous to include some ability to advise the user of a glucose level which is determined when the module is used as a “stand-alone” unit. For example, the module could include a very low cost, small three digit LCD display. Alternatively, the module could include LED indicator lights (e.g. red for out of desired range, green for within desired range). Other possibilities include a red LED for below range, a green LED for within range, and a yellow LED for above range, or a column of LEDs or an electroluminescent strip (similar to those used on common batteries to indicate battery life) to indicate approximate or relative glucose levels.
[0041] Various other modifications and alterations in the structure and method of operation of this invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. It is intended that the following claims define the scope of the present invention and that structures and methods within the scope of these claims and their equivalents be covered thereby. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a U.S. National Phase application of International application number PCT/EP2012/000458, filed Feb. 2, 2012, which claims priority benefit of European Application number 11 001 025.3, filed Feb. 9, 2011, both of which are incorporated herein by reference in their entirety for all purposes.
FIELD OF THE INVENTION
The invention relates to a packaging pouch made of a flexible mono or multilayer film for packaging viscous jelly and/or gravy matrix food, in which a thermo cycle such as retort, pasteurisation, hot filling or aseptic conditions are applicable, wherein the surface of a layer of the film forming the pouch inner walls or a surface coating on the film being in contact with food comprises a substance having the effect that the surface tension of the layer or the surface coating on the layer is 24 mN/m or less and the pouch inner walls being in contact with food exhibit easy flow properties.
BACKGROUND OF THE INVENTION
Nowadays cooked and ready meals for human and pet consumption are really common. A conspicuous part of such food is sold in flexible flat/pillow or stand-up pouches. Pouches are produced and filled in line or as a two-step production. During the filling process several ingredients are inserted in solid and liquid states while the pouch is kept open. After filling, the pouch is sealed on the top and may pass through a thermal process for pasteurisation or sterilisation. However, part of the ingredients during filling can touch the inner walls of the pouch, and if this material does not flow down inside the pouch quickly, it will contaminate the sealing area and the pouch will not be sealed completely compromising food integrity.
A possible technological solution is to use ultrasonic sealing tool that is normally an expensive investment and not suitable for all material structures. With the same principle, when the consumer will empty the pouch, part of the meal will get in contact with pouch walls, and food which is not fast flowing out of the pouch will be quite inconvenient for the consumer that would need to use tools or shake/squeeze the pouch with the risk to spread food around. In case of pet food, consumers are even less keen in using a tool or touch the food by trying to empty the pouch. This explains why having a pouch exhibiting easy and fast flowing of the food along the inner walls can strongly reduce rejections during filling, decrease food safety risk and be an important consumer convenience feature in the field of ready meals and wet pet food in pouches. As an example, ready meal pouches may contain meat, vegetables, rice in gravy or sauce added during filling and juice produced by the food during retort cooking. Pet food pouches may contain meat based food in jelly or gravy and juice produced during retort. Ready sauce pouches may be vegetable, meat or fat (eggs, butter) based and sterilised or pasteurised.
EP-A-1 808 291 discloses a packaging material made of thermoplastic polymers suitable for packaging foods. To prevent pasty and fatty foods from adhering to packaging material, a nonstick composition comprising a fatty ester of a polyhydric alcohol having at least one fatty acid radical per ester molecule with 19 or more carbon atoms is incorporated into at least one selected area of a polymer packaging material. A permanent nonstick effect is observed even if the fatty acid ester is included only in surface-close regions or layers of the packaging material. The outer layer in which the fatty acid ester additive is contained can be a sealing layer. The packaging preferably has the form of a pouch.
WO 2004/050357 A1 discloses a laminate useful in the manufacture of packages for containers, in particular ovenable resistant food containers. The laminate includes a substrate, preferably of a paperboard, and a food contact release layer comprising a blend of polymethylpentene and polypropylene bonded to one side of the substrate. The food contact release layer has a lower surface tension than the food product to come into contact with the release layer and thus offers a good release from food products, particularly those containing high levels of starch and sugar.
WO 2005/092609 A1 discloses a coextruded biaxially oriented PET film with food release properties having a sealable skin layer comprising a hot melt adhesive resin. The skin layer may further comprise fatty aides, waxes or silicon oils and particulate substances such as silica, clay and calcium carbonate.
WO 2008/009865 A1 discloses a fluoropolymer having antibacterial activity. Onto the fluoropolymer there is grafted at least one unsaturated monomer comprising a functional group functional group providing the antibacterial activity and an anion. The functional group providing antibacterial activity is a quaternary ammonium group, a phosphonium group, or a saturated or unsaturated heterocycle comprising a nitrogen atom, chosen from piperidine, piperazine, morpholine, thiomorpholine, thiazole, isothiazole, pyrazole, indole, indazole, imidazole, benzimidazole, quinoline, isoquinoline, benzotriazole, benzothiazole, benzoisothiazole, benzoxazole, benzoxazine, isoxazole, pyrrole, pyrazine, pyrimidine, pyridazine, quinazoline and acridine.
EP 1 174 457 A1 discloses a biaxially oriented polyester film with release properties in aqueous environment. The film, which is used in metal cans as inner release coating, comprises a polyester in which ethylene terephthalate units and/or ethylene naphthalate units are the main structural components, and a wax compound and for silicon compound.
U.S. Pat. No. 6,528,134 B1 discloses a coextruded film with release and dead fold properties for packaging cheese. The film comprises three layers of polyethylene or polypropylene and glycerol monostearate as cheese release agent.
From the aforementioned prior art documents, packaging films having antistick or release properties are known.
EP 2 208 604 A1 discloses a packaging pouch made of a flexible mono or multilayer film for packaging viscous jelly and/or gravy matrix food, in which a thermo cycle such as retort, pasteurisation, hot filling or aseptic conditions are applicable. The surface of a layer of the film forming the pouch inner walls or a surface coating on the film being in contact with food comprises a substance based on a molecule and or molecules system, defined as mixture of different molecular weight and/or molecular structure, functionalised by siloxane and/or fluorinated groups so that the surface tension of the layer or the surface coating on the layer is 24 mN/m or less and the pouch inner walls being in contact with food exhibit easy flow properties.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a packaging pouch made of a flexible mono or multilayer film for packaging viscous jelly and/or gravy matrix food, in which a thermo cycle such as retort, pasteurisation, hot filling or aseptic conditions may be applicable, and which exhibits easy food flow properties of the pouch inner walls being in contact with food. The surface layer of pouch inner walls being in contact with food are typically polypropylene or polyethylene based sealing layers.
DETAILED DESCRIPTION OF THE INVENTION
The aforementioned objective is achieved by way of the invention in that the substance comprises
a graft polymer having a polyolefin based acrylic copolymer backbone with the general structure
[CH 2 CRCOO(CH 2 ) p CH 3 ] x [CH 2 CR 1 COO(CH 2 ) 2 (CF 2 ) q CF 3 ] y
with R═H, CH 3 ; R 1 ═H, CH 3 ; 0<p<35; 0<q<15; 40>y/x>0.03
or
a graft polymer having a polysiloxane based acrylic copolymer backbone with the general structure
[CH 2 CRCOO(CH 2 ) p (SiO(CH 3 ) 2 ) m (SiO(CH 3 ) 3 )] x [CH 2 CR 1 COO(CH 2 ) 2 (CF 2 ) q CF 3 ] y
with R═H, CH 3 ; R 1 ═H, CH 3 ; 1<p<4; 0<q<15; 1<m<50; 40>y/x>0.03
or
a graft polymer having a polysiloxane/polyolefin based copolymer backbone with the general structure
[CH 2 CRCOO(CH 2 ) p (SiO(CH 3 ) 2 ) m (SiO(CH 3 ) 3 )] x [CH 2 CR 1 COO(CH 2 ) p CH 3 ] y
with R═H, CH 3 ; R 1 ═H, CH 3 ; 1<p<4; 0<q<15; 1<m<50; 40>y/x>0.03
or
a block structure with the extended formula
CH 3 (CH 2 ) 12 CH 2 COO(CF 2 ) 8 CONHNHCOO(CF 2 ) 8 COONHNHCO(CF 2 ) 8 COOCH 2 (CH 2 ) 12 CH 3
of the general structure
or
a micro-dispersion of ultra high molecular weight siloxane polymers with a preferred average particle size of 5 μm.
Such micro-dispersions are known as Siloxane Masterbatches (Dow Corning®), suitable products are e.g. MB50-001 and MB50-321.
Preferably the surface tension of the layer or the surface coating is 21 mN/m or less.
The pouch can withstand thermo cycles up to 135° C. for 90 min. This solution provides easy flow property also in case of aseptic filling application. A further application is related to products making problems during filling operation due to their rheology. An example is the filling of ketchup sachets where process output makes the difference on the market. Increasing the speed of filling causes problems of product spilling out from the sachet and contaminating the sealing area of the sachet. With the easy flow properties of the packaging material according to the present invention it is possible to increase the process speed without the aforementioned problems
To measure easy flow properties, there does not exist a scientific method such as for measuring the surface tension. However, it has been found that easy flow properties are correlated to surface tension. Therefore, a methodology and a tool to evaluate easy flowing has been developed by the inventors and will be explained later.
The layer of the film forming the pouch inner walls or the surface coating on the film preferably contains 0.01 to 10 wt. %, more preferably 0.5 to 3 wt. %, of the substance.
The layer of the film forming the pouch inner walls may be a coextruded layer or a monolayer. Since the substance migrates to the surface of layer of the film forming the pouch inner walls being in contact with food, an enrichment of the substance in a surface layer takes place, and consequently the concentration of the substance in this surface layer will increase with time and may therefore be higher than the overall concentration of the substance in the layer.
Preferably the surface of the layer of the film forming the pouch inner walls is polypropylene or polyethylene based.
The substance can be part of an organic or inorganic additive or filler material contained in the layer of the film forming the pouch inner walls or the surface coating on the film providing easy food flow properties. A preferred filler material is fumed silica, e.g. Aerosil® from Evonik.
The layer of the film forming the pouch inner walls can be additivated with addive or filler during production through blown or cast extrusion such as non-oriented, mono- or biaxial oriented film.
The surface coating on the film can be applied e. g. by rotogravure, flexography, spray coating, extrusion coating, curtain coating or atmospheric plasma treatment.
The packaging pouch according to the present invention can be of any shape or design, e.g. a flat pouch or a stand-up pouch, a pouch in the form of a doypack, a pillow, or a cheerpack.
With the packaging pouch according to the present invention easy flow properties are active during filling, i.e. food processing, as well as during food emptying by the consumer when the food is consumed.
The following laminates are examples of packaging materials suitable in the production of packaging pouches according to the present invention:
Polyester/adhesive/polyamide/adhesive/polypropylene
Polyester/adhesive/polyamide/adhesive/polyethylene
Polyester/adhesive/polyester/adhesive/polypropylene
Polyester/adhesive/polyester/adhesive/polyethylene
Polyester/adhesive/aluminium/adhesive/polypropylene
Polyester/adhesive/aluminium/adhesive/polyethylene
Polyester/adhesive/polyethylene
Polyester/adhesive/polypropylene
Polyester/adhesive/polyester/adhesive/polyamide/adhesive/polyethylene
Polyester/adhesive/polyester/adhesive/polyamide/adhesive/polypropylene
Polyester/adhesive/aluminium/adhesive/polyamide/adhesive/polypropylene
To provide barrier properties, polyester and/or polyamide of the above structures without aluminium can be as well coated with a ceramic material, such as SiO x or AlO x , or coated with an organic barrier material. Polyethylene and polypropylene films can be as well coextruded with EVOH and mono- or bi-oriented. Polyester films, such as PET films, can be metallised.
The polyethylene or polypropylene layer is a sealing layer forming the pouch inner walls.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, features and details of the invention are revealed in the following description of preferred exemplified embodiments and with the aid of the drawing which shows schematically in
FIG. 1 the apparatus used to evaluate easy flow properties;
FIG. 2 the top view of laminate according to the present invention and standard material at the end of the same easy flow test.
As shown in FIG. 1 , a lower end of a leaning table 10 is fixed to a hinge-joint 12 . A piston 16 of a cylinder 14 is linked to an upper end of the leaning table 10 . The piston 16 can be extended at a constant speed of 0.01 to 1 m/min.
Test strips 18 are fixed on the leaning table 10 in a horizontal starting position, i.e., the tilting angle of the leaning table 10 at the start of each test is 0°. In this position, a portion of food 20 —in the present tests a portion of ketchup—is placed onto the surface of the test strip 18 at a starting line 22 . Thereafter the leaning table is pivoted about the hinge-joint 12 from the starting position at 0° to and end position at a tilting angle of 50° within 3 minutes. Immediately when the tilting angle reaches 50°, photos of test strips are taken and visually analysed. The quantity of ketchup used in the tests are drops of 2 ml and 0.5 ml ketchup.
Wettability Tests
FIG. 2 a - e show test strips each at the end of the test. The strips shown in FIG. 2 e is a standard polypropylene film without additive, FIG. 2 a - d are based on a polypropylene film with the following additives:
FIG. 2 a : 5 wt % MB50-001
FIG. 2 b : 10 wt % MB50-001
FIG. 2 c : 5 wt % MB50-321
FIG. 2 d : 10 wt % MB50-321
Results:
Ketchup drops start moving before and faster on the modified samples ( FIG. 2 a - d ) compared to the standard sample ( FIG. 2 e )
Also the lines drawn by using a black marker are showing a different wettability, the lowest on the left and the highest on the right on the standard product where the ink is perfectly adhering on the surface.
Seal properties resulted to be in line with standard material.
All the previous evaluations were made before and after retort.
No major problems were faced during extrusion of these products.
The test results clearly demonstrate the superiority of an additive according to the present invention on the easy flow properties.
Surface Tension Tests
Surface tension measurements have been carried out on film material based on standard polypropylene (PP) with different concentration of graft polymer having a polyolefin based acrylic copolymer backbone with the general structure
[CH2CRCOO(CH2) p CH3] x [CH2CR 1 COO(CH2)2(CF2) q CF3] y
with
R═H; R 1 ═H; p=29; q=7; y/x=15 (Copolymer E)
R═H; R 1 ═H; p=29; q=7; y/x=5 (Copolymer F)
The results are presented in the following table.
Film material
Surface tension [mN/m]
Standard PP
min. 25
Standard PP + 1 and 2 wt. % Copolymer E
min. 22
Standard PP + 1 wt. % Copolymer F
min. 25.5
Standard PP + 2 wt. % Copolymer F
min. 24 | 4y
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FIELD OF THE INVENTION
This invention relates generally to book-leaf holders and especially to a device for the demarcation of selected pages of a book as a measure of reading progress incorporating a closure member for precluding the book from inadvertently being opened.
In particular, this invention concerns a combined book closure and page indexing device having resilient loop members.
2. Background Art
Conventional page indicators for books include planar strips which are interposed between the book-leaves typically, after each reading. These bookmarks are useful when the book is rested or stored on a bookshelf, library table or similar stationary support surface.
A problem with the aforementioned bookmarks is that they do not readily remain within the book and are frequently lost or otherwise misplaced. Furthermore, these bookmarks tend to become dislodged especially when the book is moved from place to place. For example, students and others who enjoy reading frequently carry reading materials by hand, in a briefcase, pocketbook, backpack or similar conveyance so that the book will be readily available for reading e.g. while in a bus, at the beach or at other locations. In these circumstances, it is advantageous to have a page indexing device which is firmly secured to the book. It is also important to provide for a book closure so that the pages of the book do not become soiled, damaged or dog-eared.
Previous attempts to provide improved book-markers or related devices are typically shown in U.S. Pat. Nos. 4,041,892; 4,162,800; 4,505,219; and 3,898,951.
A shortcoming of these devices is that they are primarily directed to marking preselected pages of a book and are not concerned with the protection of the pages in the book.
Furthermore, these patented devices do not provide the versatility and convenience of the instant invention. Additionally, they are not designed to function as an advertising display.
SUMMARY OF THE INVENTION
Briefly, the nature of this invention involves a book reader's aid which provides a page indicator for denoting previously read pages from unread pages and a book closure member for securing the book.
The combined book closure and indexing device is comprised of two interconnected continuous loops. One of the loops being adapted for placement around either a front or back cover of the book for releaseably holding a number of selected pages of the book. The other of said loops is adapted for encircling both covers for securing the book in a closed position.
The respective loops are fabricated of a stretchable material incorporating elastomeric fibers. An advertising message or similar indicia can be imprinted, woven or otherwise placed on the surface of the material.
A feature of this invention is that a page indexing loop is resiliently extendable for us with books having different dimensions.
Still another aspect of this invention is that the page indexing loop is securely affixed to the book and the book closure is therefore readily available to the user.
Furthermore, the device is particularly adapted for use as a promotional item or advertising novelty.
In view of the foregoing, it should be apparent that the present invention overcomes many of the deficiencies of the prior art and provides an improved book closure and page indexing device.
Having thus summarized the invention it will be seen that it is an object thereof to provide a combined book closure and page indexing device of the general character described herein which is not subject to the aforementioned deficiencies.
Another object of this invention is to provide a page indexing device that is attachable to a book and is adaptable for use with a range of different sized books.
Still another object of this invention is to provide a book closure device for resiliently urging the book covers toward each other to prevent free page movement.
A still further object of this invention is to provide a page indexing device for separating the previously read pages in the book from unread pages in the book.
Yet another object of this invention is to provide a book closure and page indexing device for conveying an advertising message.
Other objects of this invention will in part be apparent and in part will be pointed out hereinafter.
With these ends in view, the invention finds embodiment in certain combinations of elements and arrangement of parts by which the aforementioned objects and certain other objects are hereinafter attained, all as more fully described with reference to the accompanying drawings and the scope of which is more particularly pointed out and indicated in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings in which are shown exemplary embodiments of the invention:
FIG. 1 is a perspective view illustrating the combined book closure and page indexing device of this invention;
FIG. 2 is a perspective view of the device showing a page indexing loop applied to a book for providing page demarcation and a book closure loop attached thereto;
FIG. 3 is a perspective view of the book in FIG. 2 showing the closure loop circumscribing the book for retaining same in a closed position;
FIG. 4 is a sectional view taken substantially along lines 4--4 of FIG. 3 and further illustrating the operative arrangement of the page indexing loop and the book closure loop;
FIG. 5 is a perspective view of another size book illustrating an alternate embodiment of the invention wherein the indexing loop and the book closure loop are operatively positionable along a coincident axis; and
FIG. 6 is a sectional view to an enlarged scale showing a selectively detachable pivotal interconnection between the respective loops shown in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Referring now in detail to the drawings, the reference numeral 10 denotes generally a combined book closure and page indexing device of this invention.
The device 10 is intended for application with a range of different size books. With regard to the exemplary embodiment shown in FIG. 1, the device 10 includes a page indexing loop 12 and a book closure loop 14. Each of the loops 12, 14 is comprised of a continuous band of elastomeric material, preferably woven or braided fabric containing elastic fibers. By way of example, the loops 12, 14 are approximately 12-14 inches in length and about 1 inch in width. It should be understood however, that each of the loops 12, 14 may be of a different length and/or width e.g. the page indexing loop 12 can be as narrow as 1/8 inch. Furthermore, the loops 12, 14 can be formed as a continuous band or can be comprised of one or more band segments joined at their respective ends to form a continuous member.
As further noted in FIG. 1, the loop 12 lies substantially in a first plane and the loop 14 lies in a second plane displaced 90 degrees from the first plane. The purpose of this orthogonal relationship between the loops 12, 14 is to assure that the respective loops 12, 14 will lie parallel to and on the surfaces of the book.
Furthermore, the fabric construction of the loops 12, 14 provides a medium for bearing indicia such as an advertising slogan, a company name, or other promotional material. Thus, the device 10 also provides an advertising novelty for conveying messages.
The loops 12, 14 are interconnected at a point of intersection of the planes providing a common locus 16. The connection of the respective loops 12, 14 is accomplished by stitching 18 although alternative methods such as complementary velcro strips, buttons, ribbons, snaps or similar fasteners may be employed for accomplishing this result.
FIG. 2 illustrates the page indicating function of the device 10 and shows a book 20 having a front cover 22 and a back cover 23 and a plurality of sheets or pages 24 carried therebetween. The page indexing loop 12 encircles the front cover 22 of the book 20 and the pages 24. It should thus be apparent that the indexing loop 12 is adaptable for separating the read pages from the unread portion of the book 20. The elasticity of the loop 12 provides for yieldable engagement over a range of pages 24. It should also be noted that the book closure loop 14 is secured to the page indexing loop 12 and is therefore readily available when one has completed reading a portion of the book 20. The orthogonal arrangement of the respective loops 12, 14 as previously mentioned, is suitable for providing contiguous encirclement of the book 20 by the closure loop 14. As will be observed in FIG. 3, not only is the indexing loop 12 secured in place, but the pages 24 of the book 20 are yieldably held between the respective book covers 22, 23 and are thus protected from damage. It should thus be apparent that the book 20 can be deposited within a carry-case or other travel bag without displacement of the page indexing loop 12 or damage to the pages 24.
An alternate embodiment of the invention is illustrated in FIGS. 5 and 6 wherein a snap fastener 18a replaces the previous stitched loop connection at the common locus 16. The snap fastener 18a includes a socket 26 and a ball member 28 adapted for snap-fit engagement within the socket 26. Furthermore, when engaged, the snap fastener 18a provides for rotational displacement to thus permit registered alignment or other non-orthogonal orientation of the respective loops 12a, 14a.
As shown in FIG. 5, the loops 12a, 14a can thus be placed around a book 20a along a coincident axis. This arrangement is particularly advantageous with books having an extensive length dimension as compared to the height dimension and therefore permits the encirclement around the height dimension as shown in FIG. 5.
Furthermore, the detachability of the loops 12a, 14a by use of the snap fastener 18a, provides additional versatility in that different size loops can be combined as may be required for accommodating a specific book. It should also be apparent that a Velcro, hook and eye connection, can also be utilized for additional flexibility in combining loop members.
It should thus be seen that there is provided a combined book closure and page indexing device which achieves the various objects of this invention and which is well adapted to meet conditions of practical use.
Since various possible embodiments might be made of the present invention or modifications might be made to the exemplary embodiments set forth, it is to be understood that all materials shown and described in the accompanying drawings are to be interpreted as illustrative and not a limiting sense.
With these ends in view, the invention finds embodiment in certain combinations of elements and arrangement of parts by which the aforementioned objects and certain other objects are hereinafter attained, all as more fully described with reference to the accompanying drawings and the scope of which is more particularly pointed out and indicated in the appended claims. | 4y
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FIELD OF THE INVENTION
The present invention relates to diesel power generation systems with exhaust aftertreatment.
BACKGROUND
NO x emissions from diesel engines are an environmental problem. Several countries, including the United States, have long had regulations pending that will limit NO x emissions from trucks and other diesel-powered vehicles. Manufacturers and researchers have put considerable effort toward meeting those regulations.
In gasoline powered vehicles that use stoichiometric fuel-air mixtures, three-way catalysts have been shown to control NO X emissions. In diesel-powered vehicles, which use compression ignition, the exhaust is generally too oxygen-rich for three-way catalysts to be effective.
Several solutions have been proposed for controlling NO X emissions from diesel-powered vehicles. One set of approaches focuses on the engine. Techniques such as exhaust gas recirculation and partially homogenizing fuel-air mixtures are helpful, but these techniques alone will not eliminate NO X emissions. Another set of approaches remove NO X from the vehicle exhaust. These include the use of lean-burn NO X catalysts, selective catalytic reduction (SCR) catalysts, and lean NO X traps (LNTs).
Lean-burn NO X catalysts promote the reduction of NO x under oxygen-rich conditions. Reduction of NO X in an oxidizing atmosphere is difficult. It has proven challenging to find a lean-burn NO x catalyst that has the required activity, durability, and operating temperature range. A reductant such as diesel fuel must be steadily supplied to the exhaust for lean NO X reduction, introducing a fuel economy penalty of 3% or more. Currently, peak NO X conversion efficiencies for lean-burn NO X catalysts are unacceptably low.
SCR generally refers to selective catalytic reduction of NO X by ammonia. The reaction takes place even in an oxidizing environment. The NO X can be temporarily stored in an adsorbent or ammonia can be fed continuously into the exhaust. SCR can achieve high levels of NO X reduction, but there is a disadvantage in the lack of infrastructure for distributing ammonia or a suitable precursor. Another concern relates to the possible release of ammonia into the environment.
LNTs are devices that adsorb NO X under lean exhaust conditions and reduce and release the adsorbed NO X under rich conditions. An LNT generally includes a NO X adsorbent and a catalyst. The adsorbent is typically an alkaline earth compound, such as BaCO 3 and the catalyst is typically a combination of precious metals including Pt and Rh. In lean exhaust, the catalyst speeds oxidizing reactions that lead to NO X adsorption. In a reducing environment, the catalyst activates reactions by which hydrocarbon reductants are converted to more active species, the water-gas shift reaction, which produces more active hydrogen from less active CO, and reactions by which adsorbed NO X is reduced and desorbed. In a typical operating protocol, a reducing environment will be created within the exhaust from time-to-time to regenerate (denitrate) the LNT.
Regeneration to remove accumulated NOx may be referred to as denitration in order to distinguish desulfation, which is carried out much less frequently. The reducing environment for denitration can be created in several ways. One approach uses the engine to create a rich exhaust-reductant mixture. For example, the engine can inject extra fuel into the exhaust within one or more cylinders prior to expelling the exhaust. A reducing environment can also be created by injecting a reductant into lean exhaust downstream from the engine. In either case, a portion of the reductant is generally expended to consume excess oxygen in the exhaust. To lessen the amount of excess oxygen and reduce the amount of reductant expended consuming excess oxygen, the engine may be throttled, although such throttling may have an adverse effect on the performance of some engines.
Reductant can consume excess oxygen by either combustion or reforming reactions. Typically, the reactions take place upstream of the LNT over an oxidation catalyst or in a fuel reformer. The reductant can also be oxidized directly in the LNT, but this tends to result in faster thermal aging. U.S. Pat. Pub. No. 2004/0050037 (hereinafter “the '037 publication”) describes an exhaust system with a fuel reformer placed in an exhaust line upstream from an LNT. The reformer includes both oxidation and reforming catalysts. The reformer both removes excess oxygen and converts the diesel fuel reductant into more reactive reformate.
The oxidation and reforming catalysts of the '037 publication are subject to harsh conditions. According the '037 publication, it is desirable to heat the fuel reformer to steam reforming temperatures for each LNT regeneration and to pulse the fuel injection during regeneration to prevent the fuel reformer from overheating. Pulsing causes the catalyst to alternate between lean and rich conditions while at high temperature. The catalyst itself tends to undergo chemical changes through this cycling, which can lead to physical changes, especially sintering, which is the growth of catalyst particles. As the particles grow, their surface area and number of surface atoms decrease, resulting in a less active catalyst.
Numerous choices are available for the oxidation and reforming catalysts, With regard to the oxidation catalyst, the '037 patent lists Pd, Pt, Ir, Rh, Cu, Co, Fe, Ni, Ir, Cr, and Mo as possible choices, without limitation. The catalyst support is also important. The '037 patent lists as examples, without limitation, cerium zirconium oxide mixtures or solid solutions, silica alumina, Ca, Ba, Si, or La stabilized alumina. Many other oxidation catalysts, supports, and stabilizers are known in the art. Likewise, many examples or reforming catalysts are known. The '037 patent list Ni, Rh, Pd, and Pt as possible reforming catalysts, without limitation. As with the oxidation catalyst, a wide range of supports and stabilizers could be considered for use.
In spite of advances, there continues to be a long felt need for an affordable and reliable diesel exhaust aftertreatment system that is durable, has a manageable operating cost (including fuel penalty), and reduces NO X emissions to a satisfactory extent in the sense of meeting U.S. Environmental Protection Agency (EPA) regulations effective in 2010 and other such regulations.
SUMMARY
After considerable research, the inventors have developed oxidation and reforming catalysts for use in diesel exhaust aftertreatment systems. The catalysts are economical and superior in terms of durability under lean-rich cycling at high temperatures. The catalysts comprise precious metals supported on La stabilized refractory metal oxides. The La is distributed on the surface of the refractory metal oxide support in an amount to form at least about a monolayer, preferably about 1-2 monolayers. Preferably, the La is substantially amorphous in the sense of having no crystalline structure shown by X-ray diffraction. Nd and mixtures of La and Nd can be used in place of La. The La is typically in an oxide form and the precious metal may be either reduced or in oxide form.
In one embodiment, the catalyst is a reforming catalyst comprising an effective amount of Rh on a ZrO 2 support. The catalyst preferably comprises from about 0.5 to about 1.0 mg La per m 2 refractory metal oxide surface distributed over the surface. For a typical ZrO 2 support that has a surface area of about 100 m 2 /g, this gives from about 5 to about 10% La by weight refractory metal oxide. The catalyst preferably also comprises from about 0.01 to about 0.1 mg Rh per m 2 refractory metal oxide surface area. The Rh is distributed on the surface of the refractory metal oxide particles along with or over the La. For the typical ZrO 2 support, this loading gives from about 0.1 to about 1.0% Rh by weight refractory metal oxide. The Rh is present in an amount effective to catalyze steam reforming of diesel fuel at 650° C. Preferably, the Rh has an average particle size of under 5 nm and the catalyst is functional to maintain the Rh particle size under 5 nm through 400 25 minute lean/25 minute rich lean/rich cycles at 750° C. Preferably, the Rh has a dispersion of at least about 40% and the catalyst is functional to maintain a dispersion of at least about 40% through 400 25 minute lean/25 minute rich lean/rich cycles at 750° C. Preferably, the catalyst comprises little or no platinum.
According to a further aspect of the invention, the Rh is provided in a relatively low concentration: from about 0.01 to about 0.05 mg per m 2 refractory metal oxide surface area, which corresponds to about 0.1 to about 0.5% Rh by weight refractory metal oxide for the typical ZrO 2 support. The inventors have found that if the Rh loading is kept sufficiently low, the Rh can be maintained in the form of small particles (less than 5 nm, typically about 2 nm or less) while the catalyst undergoes lean-rich cycling through an effect involving the La. The improvement in stability is such that as the Rh loading is reduced from about 0.10 mg/m 2 to about 0.05 mg/m 2 or less, nearly the same or greater catalyst activity results after aging than is achieved with the larger Rh loading.
In another embodiment, the catalyst is an oxidation catalyst comprising an effective amount of Pd on an Al 2 O 3 refractory metal oxide support. The catalyst preferably comprises from about 0.5 to about 1.0 mg La per m 2 refractory metal oxide distributed over the surface of the refractory metal oxide particles. For a typical Al 2 O 3 refractory metal oxide support that has a surface area of about 200 m 2 /g, this corresponds to from about 10 to about 20% La by weight refractory metal oxide. The catalyst preferably also comprises from about 0.25 to about 1.0 mg Pd per m 2 refractory metal oxide surface area, which corresponds to from about 5 to about 20% Pd by weight refractory metal oxide for the typical Al 2 O 3 refractory metal oxide support. The Pd is present in an amount effective for the oxidation catalyst to light off at 275° C., more preferably at 240° C. Preferably, the Pd has an average particle size of under 10 nm and is functional to maintain a particle size under 10 nm through 400 hours of 25 minute lean/25 minute rich lean/rich aging at 750° C. Preferably, the Pd has a dispersion of at least about 15% and the catalyst is functional to maintain a dispersion of at least about 15% through 400 hours of aging in a lean atmosphere comprising 10% steam at 750° C.
A further aspect of the invention relates to a method of operating a power generation system comprising operating a diesel engine to produce lean exhaust and passing the exhaust through a fuel reformer and a lean NO X trap in that order, whereby a portion of the NO X in the exhaust is absorbed by the lean NO X trap. From time-to-time, a control signal to regenerate the lean NO X trap is produced. In response to the control signal, diesel fuel is injected into the exhaust upstream from the fuel reformer at a rate that makes the exhaust-fuel mixture overall lean, whereby the injected fuel combusts within the fuel reformer raising the temperature of the fuel reformer. After the fuel reformer has heated to at least about 500° C., a rich phase is initiated by increasing the fuel injection rate and/or lowering the exhaust oxygen flow rate to cause the exhaust-injected fuel mixture to become overall rich, whereby the fuel reformer produces reformate that regenerates the lean NO X trap. The fuel reformer comprises oxidation and reforming catalysts. The reforming catalyst comprises a catalyst washcoat comprising a ZrO 2 refractory metal oxide support, a Ln X O Y distributed on the surface of the refractory metal oxide in an amount at least sufficient to form about a monolayer over the refractory metal oxide support, wherein Ln is selected from the group consisting of La, Nd, and mixtures thereof, and Rh distributed over the catalyst surface in an effective amount to catalyze steam reforming at 650° C. In one embodiment, the method further comprises discontinuing the fuel injection to allow the fuel reformer to cool in a lean phase and cycling repeatedly between the rich and lean phases to complete the regeneration of the lean NO X trap. This pulsed operation creates harsh operating conditions to which the claimed compositions are particularly well adapted.
The primary purpose of this summary has been to present certain of the inventors' concepts in a simplified form to facilitate understanding of the more detailed description that follows. This summary is not a comprehensive description of every one of the inventors' concepts or every combination of the inventors' concepts that can be considered “invention”. Other concepts of the inventors will be conveyed to one of ordinary skill in the art by the following detailed description together with the drawings. The specifics disclosed herein may be generalized, narrowed, and combined in various ways with the ultimate statement of what the inventors claim as their invention being reserved for the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of an exemplary exhaust aftertreatment system that can embody various concepts described herein.
FIG. 2 Surface Rh in micromoles per g ZrO 2 on a 5% La/ZrO 2 support as a function of time under cyclic aging for various Rh loadings.
FIG. 3 shows the stability under steam aging of 10% Pd co-dispersed with various amounts of La on a commercially available La-stabilized Al 2 O 3 support.
DETAILED DESCRIPTION
The catalysts of the present disclosure are adapted to a particular application. FIG. 1 is a schematic illustration of an exemplary power generation system 100 embodying that application. The power generation system 100 is not the only power generation system to which the inventors' concepts are applicable, but the various concepts described herein were originally developed for systems like the system 100 and the individual components of the system 100 pertain to preferred embodiments. The power generation system 100 comprises a diesel engine 101 and an exhaust line 102 in which are configured components of an exhaust aftertreatment system 103 . The exhaust aftertreatment system 103 comprises a fuel reformer 104 , a lean NO X trap 105 , and an ammonia-SCR catalyst 106 . A fuel injector 107 is configured to inject fuel into the exhaust line 102 upstream from the fuel reformer 104 . A controller 108 controls the fuel injection based on information about the operating state of the engine 101 , a temperature of the fuel reformer 104 measured by a temperature sensor 109 , and a NO X concentration measurement obtained by the NO X sensor 110 at a point in the exhaust line 102 downstream from the lean NO X trap 105 . A temperature sensor 111 is configured to measure the temperature of the lean NO X trap 105 , which is particularly important during desulfation.
The diesel engine 101 is a compression ignition engine. A compression ignition diesel engine normally produces exhaust having from about 4 to about 21% O 2 . An overall rich exhaust-reductant mixture can be formed by injecting diesel fuel into the exhaust during cylinder exhaust strokes, although it is preferred that any reductant injection into the exhaust take place downstream from the engine 101 . The engine 101 is commonly provided with an exhaust gas recirculation (EGR) system and may also be configured with an intake air throttle, either of which can be used to reduce the exhaust oxygen concentration and lessen the amount of reductant required to produce an overall rich exhaust-reductant mixture. A lean burn gasoline engine or a homogeneous charge compression ignition engine can be used in place of the engine 101 . The engine 101 is operative to produce an exhaust that comprises NO X , which is considered to consist of NO and NO 2 .
The engine 101 is generally a medium or heavy duty diesel engine. The inventors' concepts are applicable to power generation systems comprising light duty diesel and lean burn gasoline engines, but the performance demands of exhaust aftertreatment systems are generally greater when the engine is a medium and heavy duty diesel engine. Minimum exhaust temperatures from lean burn gasoline engines are generally higher than minimum exhaust temperatures from light duty diesel engines, which are generally higher than minimum exhaust temperatures from medium duty diesel engines, which are generally higher than minimum exhaust temperatures from heavy duty diesel engines. Lower exhaust temperatures make NO X mitigation more difficult and place lower temperature light off requirements on fuel reformers. A medium duty diesel engine is one with a displacement of at least about 4 liters, typically about 7 liters. A heavy duty diesel engine is one with a displacement of at least about 10 liters, typically from about 12 to about 15 liters.
A light-off temperature for the fuel reformer 104 is an exhaust temperature at which when the fuel reformer 104 can be heated substantially above the exhaust temperature by combusting within the fuel reformer 104 fuel injected into the exhaust line 102 through the fuel injector 107 . Typically, once the fuel reformer 104 has lit off, the fuel reformer 104 will remain substantially above the exhaust temperature even if the exhaust temperature is lowered somewhat below the light-off temperature, provided the fuel injection continues.
The exhaust from the engine 101 is channeled by a manifold to the exhaust line 102 . The exhaust line 102 generally comprises a single channel, but can be configured as several parallel channels. The exhaust line 102 is preferably configured without exhaust valves or dampers. In particular, the exhaust line 102 is preferably configured without valves or dampers that could be used to vary the distribution of exhaust among a plurality of LNTs 105 in parallel exhaust channels. Valves or dampers can be used to reduce the exhaust flow to a fuel processor or LNT, allowing regeneration to be carried out efficiently even when exhaust conditions are unfavorable. Nevertheless, it is preferred that the exhaust line 102 be configured without valves or dampers because these moving parts are subject to failure and can significantly decrease the durability and reliability of an exhaust aftertreatment system.
Even when the exhaust line 102 is free from exhaust valves or dampers, an exhaust line upstream from the exhaust line 102 may still contain an exhaust valve, such as an exhaust gas recirculation (EGR) valve in an EGR line. Exhaust valves are particularly problematic when they are configured within a main exhaust line to divert a majority of the exhaust flow as compared to exhaust valves configured to control the flow through a side branch off a main exhaust line. Exhaust valves for larger conduits are more subject to failure than exhaust valves for smaller conduits.
The exhaust line 102 is provided with an exhaust line fuel injector 107 to create rich conditions for LNT regeneration. The inventors' concepts are applicable to other method's of creating a reducing environment for regenerating the LNT 105 , including engine fuel injection of reductant and injection of reductants other than diesel fuel. Nevertheless, it is preferred that the reductant is the same diesel fuel used to power the engine 101 . It is also preferred that the reductant be injected into the exhaust line 102 , rather than into the cylinders of engine 101 , in order to avoid oil dilution caused by fuel passing around piston rings and entering the oil gallery. Additional disadvantages of cylinder reductant injection include having to alter the operation of the engine 101 to support LNT regeneration, excessive dispersion of pulses of reductant, forming deposits on any turbocharger configured between the engine 101 and the exhaust line 102 , and forming deposits on any EGR valves.
The diesel fuel is injected into the exhaust line 102 upstream from the fuel reformer 104 . The fuel reformer 104 comprises an effective amount of precious metal catalysts to catalyze oxidation reactions at 275° C. and steam reforming reactions at 650° C. The fuel reformer 104 is designed with low thermal mass, whereby it can be easily heated to steam reforming temperatures for each LNT regeneration. Low thermal mass is typically achieved by constructing the fuel reformer 104 using a thin metal substrate to form a monolith structure on which the catalyst or catalysts are coated. A thin metal substrate has a thickness that is about 100 μm or less, preferably about 50 μm or less, and still more preferably about 30 μm or less.
Oxidation and reforming catalysts can be co-dispersed on the fuel reformer 104 , but preferably, they are applied separately. The oxidation catalyst preferably forms a coating beginning proximate an inlet of the monolith and continuing part way toward or entirely to an outlet of the monolith. The reforming catalyst preferably forms a coating beginning proximate the outlet and continuing part way or entirely toward the inlet. In one embodiment, the reforming catalyst does not proceed entirely to the inlet, whereby injected fuel undergoes a substantial degree of reaction over the oxidation catalyst prior to encountering the reforming catalyst. The oxidation and reforming catalysts can occupy disjoint areas, abutting areas, or overlapping areas.
If the catalyst areas do overlap, either catalyst can be uppermost. Making the reforming catalyst uppermost has the advantage that it contact the reactants after the least diffusion. This is the preferred configuration if the reforming catalyst proceeds only partly toward the inlet. The reforming catalyst is more expensive than the oxidation catalyst, and it is therefore desirable that it be utilized as efficiently as possible. The oxidation catalyst, on the other hand, is least costly and can often be provided in greater quantity when more oxidation catalyst activity is desired. An advantage of applying the oxidation catalyst in a manner where the oxidation catalyst extends into the region under the reforming catalyst is that additional oxidation catalysis can be achieved in the same volume with essentially the same substrate thermal mass at relatively little extra expense as compared to the case where the oxidation catalyst terminates approximately where the reforming catalyst begins. On the other hand, making the oxidation uppermost has the advantage of increasing the extent of oxidation prior to contact with the reforming catalyst. This is the preferred configuration of the reforming catalyst extends to the inlet.
Steam reforming temperatures are at least about 500° C., which is generally above diesel exhaust temperatures. Diesel exhaust temperatures downstream from a turbocharger vary from about 110 to about 550° C. Preferably, the fuel reformer 104 can be warmed up and operated using diesel fuel from the injector 107 stating from an initial temperature of 275° C. while the exhaust from the engine 101 remains at 275° C. More preferably, the fuel reformer 104 can be warmed up and operated from initial exhaust and reformer temperatures of 240° C., and still more preferably from exhaust and reformer temperatures of 210° C. These properties are achieved by providing the fuel reformer 104 with effective amounts of precious metals, such as Pd, for catalyzing oxidation of diesel fuel at the starting temperatures. Low temperature start-up can also be improved by configuring a low thermal mass precious metal oxidation catalyst upstream from the fuel reformer 104 . Preferably, the upstream catalyst combusts a portion of the fuel while vaporizing the rest. A mixing zone between the upstream catalyst and the fuel reformer 104 is also helpful.
The fuel reformer 104 is designed to light-off at relatively low temperature. Light-off is the phenomena whereby the fuel reformer 104 heats to approach a steady state temperature that is substantially above the exhaust temperature. Once lit off, the fuel reformer 104 has a tendency to remain heated even when the conditions bringing about light off are discontinued. Preferably, the fuel reformer 104 is adapted to light-off when the exhaust temperature is as low as about 275° C., more preferably when the exhaust temperature is as low as about 240° C., still more preferably when the exhaust temperature is as low as about 210° C.
The fuel reformer 104 is design to warm up to and produce reformate at steam reforming temperatures. Operation at steam reforming temperatures reduces the total amount of precious metal catalyst required. Having the fuel reformer 104 operate at least partially through steam reforming reactions significantly increases the reformate yield and reduces the amount of heat generation. In principal, if reformate production proceeds through partial oxidation reforming as in the reaction:
CH 1.85 +0.5O 2 →CO+0.925H 2 (1)
1.925 moles of reformate (moles CO plus moles H 2 ) could be obtained from each mole of carbon atoms in the fuel. CH 1.85 is used to represent diesel fuel having a typical carbon to hydrogen ratio. If reformate production proceeds through steam reforming as in the reaction:
CH 1.85 +H 2 O→CO+1.925H 2 (2)
2.925 moles of reformate (moles CO plus moles H 2 ) could in principle be obtained from each mole of carbon atoms in the fuel. In practice, yields are lower than theoretical amounts due to the limited efficiency of conversion of fuel, the limited selectivity for reforming reactions over complete combustion reactions, the necessity of producing heat to drive steam reforming, and the loss of energy required to heat the exhaust.
Preferably, the fuel reformer 104 comprises enough steam reforming catalyst that at 650° C., with an 8 mol % exhaust oxygen concentration from the engine 101 and with sufficient diesel fuel to provide the exhaust with an overall fuel to air ratio of 1.2:1, at least about 2 mol % reformate is generated by steam reforming, more preferably at least about 4 mol %, and still more preferably at least about 6 mol %. For purposes of this disclosure, functional descriptions involving diesel fuel are tested on the basis of the No. 2 diesel fuel oil sold in the United States, which is a typical diesel fuel.
An LNT is a device that adsorbs NO X under lean conditions and reduces NO X and releases NO X reduction products under rich conditions. An LNT generally comprises a NO X adsorbent and a precious metal catalyst in intimate contact on an inert support. Examples of NO X adsorbent materials include certain oxides, carbonates, and hydroxides of alkali and alkaline earth metals such as Mg, Ca, Sr, and Ba or alkali metals such as K or Cs. The precious metal typically consists of one or more of Pt, Pd, and Rh. The support is typically a monolith, although other support structures can be used. The monolith support is typically ceramic, although other materials such as metal and SiC are also suitable for LNT supports. The LNT 105 may be provided as two or more separate bricks.
The ammonia-SCR catalyst 106 is functional to catalyze reactions between NO X and NH 3 to reduce NO X to N 2 in lean exhaust. The ammonia-SCR catalyst 106 adsorbs NH 3 released from the LNT 105 during denitration and subsequently uses that NH 3 to reduce NO X slipping from the LNT 105 under lean conditions. Examples of ammonia-SCR catalysts include certain oxides of metals such as Cu, Zn, V, Cr, Al, Ti, Mn, Co, Fe, Ni, Mo, W, and Ce and zeolites, such as ZSM-5 or ZSM-11, substituted with metal ions such as cations of Cu, Co, Ag, or Zn. Ammonia-SCR can be accomplished using certain precious metals, but preferably the SCR catalyst 106 is substantially free of precious metals. Preferably, the ammonia-SCR catalyst 106 is designed to tolerate temperatures required to desulfate the LNT 105 .
The exhaust aftertreatment system 100 can comprise other components, such as a diesel particulate filter and a clean-up oxidation catalyst. A thermal mass can be placed between the fuel reformer 104 and the LNT 105 to protect the LNT 105 from frequent exposure to high fuel reformer temperatures. A diesel particulate filter can be used as the thermal mass.
During normal operation, the engine 101 produces an exhaust comprising NO X , particulate matter, and excess oxygen. A portion of the NO X is adsorbed by the LNT 105 . The ammonia-SCR catalyst 106 may have ammonia stored from a previous denitration of the LNT 105 . If the ammonia-SCR catalyst 106 contains stored ammonia, an additional portion of the NO X is reduced over the ammonia-SCR catalyst 106 by reaction with stored ammonia. The fuel injector 107 is generally inactive over this period, although small fuel injections might be used to maintain the fuel reformer 104 at a temperature from which it can be easily heated or to maintain the lean NO X trap 105 at a temperature at which it effectively absorbs NO X .
From time-to-time, the LNT 105 must be regenerated to remove accumulated NO X (denitrated). Denitration generally involves heating the fuel reformer 104 to an operational temperature and then using the reformer 104 to produce reformate. The reformer 104 is generally heated by injecting fuel into the exhaust upstream from the fuel reformer 104 at a sub-stoichiometric rate, whereby the exhaust-reductant mixture remains overall lean and most of the injected fuel completely combusts in the reformer 104 . This may be referred to as a lean warm-up phase. Once combustion has heated the reformer 104 , the fuel injection rate can be increased and/or the exhaust oxygen flow rate reduced to make the exhaust-reductant mixture overall rich, whereupon the reformer 104 consumes most of the oxygen from the exhaust and produces reformate by partial oxidation and steam reforming reactions. The reformate thus produced reduces NO X absorbed in the LNT 105 . Some of the NO X may be reduced to NH 3 , which is absorbed and stored by the ammonia-SCR catalyst 106 .
From time to time, the LNT 105 must also be regenerated to remove accumulated sulfur compounds (desulfated). Desulfation involves heating the fuel reformer 104 to an operational temperature, heating the LNT 105 to a desulfating temperature, and providing the heated LNT 105 with a rich atmosphere. Desulfating temperatures vary, but are typically in the range from about 500 to about 800° C., with optimal temperatures typically in the range of about 650 to about 750° C. Below a minimum temperature, desulfation is very slow. Above a maximum temperature, the LNT 105 may be damaged.
The LNT 105 is heated for desulfation in part by heat convection from the reformer 104 . To generate this heat, fuel can be supplied to the reformer 104 under lean conditions, whereby the fuel combusts in the reformer 104 . Once the reformer 104 is heated, the fuel injection rate can be controlled to maintain the temperature of the reformer 104 while the LNT 105 heats. Heating of the LNT 105 can be facilitated, and the temperature of the LNT 105 in part maintained, by frequently switching between lean and rich phases, whereby some oxygen from the lean phases reacts with some reductant from the rich phases within the LNT 105 . The contribution of this method to heating the LNT 105 can be regulated through the frequency of switching between lean and rich phases.
During rich operation for either denitration or desulfation, the fuel reformer 104 tends to heat. Particularly when the exhaust oxygen concentration is at about 8% or higher, the heat produced removing oxygen from the exhaust tends to be greater than the heat removed by endothermic steam reforming, regardless of the fuel injection rate. Theoretically, increasing the fuel injection rate increases the proportion of endothermic steam reforming, but in practice this is not always effective to prevent the fuel reformer 104 from heating during rich operation. As a result, the, fuel reformer 104 's temperature rises. To prevent overheating, fuel injection can be stopped and the fuel reformer 104 can be allowed to cool for a period before resuming rich regeneration. This results in alternating lean-rich condition within the fuel reformer 104 at high temperature. Operation at high temperatures and cycling between lean and rich conditions are detrimental to many catalysts.
The fuel reformer 104 preferably comprises both oxidation and reforming catalysts. When the exhaust-fuel mixture supplied to the fuel reformer is overall lean, the oxidation catalyst functions to combust nearly all the fuel and the reforming catalyst has little or no excess fuel to reform. When the fuel reformer has been heated sufficiently and the exhaust fuel mixture supplied to the fuel reformer is overall rich, the oxidation catalyst functions to combust a portion of the fuel to consume most of the oxygen in the exhaust and the reforming catalyst functions to generate syn gas through endothermic steam reforming. Preferably, the oxidation and reforming catalysts are in close proximity, whereby heat generated over the oxidation catalyst maintains the temperature of the fuel reforming catalyst.
Rh appears to be the most efficient steam reforming catalyst for the conditions created by the system 100 . The effectiveness of rhodium depends on its dispersion. As an absolute number, dispersion is the number of surface-exposed rhodium atoms per gram. As a percentage, dispersion is the fraction of Rh that can be considered to be on the surface, in terms of its availability for reaction. The fraction of surface Rh depends on the average particle size of the Rh metal or Rh metal oxide. A catalyst with 1 wt % Rh loading and 100% dispersion (all surface Rh) would provide 97.1 μmoles surface Rh/g. Rh dispersion can be measured by chemisorption of H 2 . For the present application, not only is a high initial dispersion of Rh desirable, but also a high dispersion after extensive lean operation and lean-rich cycling at elevated temperatures.
The inventors have evaluated several refractory metal oxide supports for Rh in the reforming catalyst. TiO 2 was determined to have insufficient thermal durability. Pure alumina is known to react with Rh. In an attempt to prevent such reaction, the alumina was pre-coated with La 2 O 3 (e.g., 10% by weight alumina). At 1% Rh loading, initial dispersions of Rh were good, e.g., 70% dispersion and 1-2 nm rhodium particle size. After lean aging with 10% steam for 400 hours at 700° C., however, the rhodium dispersion was reduced to 10%. Using TGA, it was determined that 50% of the rhodium was no longer in the form of Rh particles (metal or oxide), suggesting it had dissolved in the La or alumina. Notably, such loss of particulate rhodium did not occur over 1000 hours of lean rich aging 750° C.
Lean rich aging, as the term is used herein, refers to the following processing or equivalents thereof. In a lean portion of the cycle, the catalyst is exposed to air with 10% steam for 25 minutes. In a rich portion of the cycle, the catalyst is exposed to nitrogen having 3.8% hydrogen and mixed with 10% steam for 25 minutes. In between the lean and rich portions of the cycle, the catalyst is flushed with nitrogen for 5 minutes. The absence of reduction in available rhodium after 1000 hours of lean rich aging 750° C. suggests that La in amounts sufficient to form at least about a monolayer coating over the refractory metal oxide can redistribute Rh under rich conditions.
Depositing 1% Rh on a La-stabilized ZrO 2 gave significantly better results than La-stabilized alumina under lean aging. At a 2.5% La loading, the Rh dispersion was 29% after steam aging for 400 hours at 700° C. 2.5% La on a 100 m 2 /g refractory metal oxide, which is the approximate surface area of the ZrO 2 support used in the experiments reported herein, corresponds to about a monolayer. When the amount of La is increased to 5%, the dispersion was 42% after steam aging for 400 hours at 700° C. Accordingly, a preferred reforming catalyst includes a ZrO 2 refractory metal oxide component. Preferably, the refractory metal oxide component consists essentially of ZrO 2 . The ZrO 2 exists as submicron particles. Typical ZrO 2 surface areas are in the range from 70 to 130 m 2 /g.
Rh and La 2 O 3 can be applied to the surfaces of the ZrO 2 particles by any suitable technique. Suitable techniques include precipitation and impregnation. Impregnation of Rh begins by adding Rh salts or nitric acid solutions of Rh salts to water. The water volume is adjusted to be slightly more (about 10% more) than the pore volume of the refractory oxide support. Exemplary rhodium salts include rhodium chloride and rhodium nitrate. After impregnation, the supports are dried at 150° C. for 2-3 hours. The dried powder is then calcined at 450° C. for two hours and finally calcined at 600-800° C. for four hours. Deposition of Rh from rhodium nitrate solution gives comparable dispersion to deposition of Rh from rhodium chloride, but rhodium nitrate has the advantage of being less corrosive. The Rh and the La can be incorporated in the same solution and impregnated onto the ZrO 2 in a single step or the Rh and La can be in separate solutions and incorporated onto the ZrO 2 in separate steps with a drying step in between each impregnation. Deposition of La 2 O 3 prior to deposition of Rh in a two step process appears to give higher stability than deposition of La 2 O 3 and Rh simultaneously in a one step process. The La and the Rh can be applied to the ZrO 2 either before or after the ZrO 2 is applied to a substrate such as a metal monolith.
Tables 1 and 2 show a series of results pertaining to the stability under aging of 1% Rh/ZrO 2 catalyst having various amounts of La 2 O 3 . The La 2 O 3 is deposited on the surface of the ZrO 2 particles together with the Rh. 1% La appears to be insufficient to impart the desired stability under lean-rich cycling. 2.5% La based on the weight of the refractory metal oxide, has a significant beneficial effect. Further increasing the La loading to 5% or greater appears to provide a further improvement. Additional La loading at least up to about 20% does not appear to have any detrimental effect, but does not result in very significant further improvements. There was some indication that thicker La 2 O 3 coatings would result in a separate La 2 O 3 phase. Accordingly, it is preferred that the La loading be about 10% or less for the 100 m 2 /g refractory metal oxide. Preferably, the La 2 O 3 is amorphous. An amorphous layer, as the term is used herein, is one that has no apparent crystalline structure shown by X-ray diffraction. A La 2 O 3 particle with an average particle size of about 1 nm or less would not show a crystalline X-ray diffraction pattern.
TABLE 1
Rh dispersion results (%) for 1% Rh/ZrO 2 catalysts with
varying amount of La after various periods of lean aging in 10%
steam at 700° C.
4 hrs
100 hrs
500 hrs
600 hrs
1% La
47
2.5% La
72
24
29
20
2.5% La
66
29
5% La
64
30
41
24
5% La
78
42
7.5% La
67
32
25
10% La
64
35
18
TABLE 2
Rh dispersion results (%) for 1% Rh/ZrO 2 catalysts with
varying amount of La after various periods of cyclic lean-rich aging at
750° C.
4 hrs
108 hrs
250 hrs
500 hrs
1% La
74
13
9
5
2.5% La
75
34
19
5% La
76
65
18
Table 3 shows the effect of Rh loading for a 5% La/ZrO 2 support. Dispersion on a percentage basis for aged samples improves as Rh loading decreases to a very surprising extent. As the Rh loading is decreased from 1% to about 0.5%, the dispersion after 120 hours aging increases to such an extent that the same or greater Rh activity (amount of surface Rh) is achieved with the smaller amount of Rh. As the Rh loading is further decreased to 0.25%, Rh dispersion continues to increase, whereby the Rh activity decreases only slightly as Rh loading is reduced from 0.5% to 0.25%. It appears that the Rh sinters to a markedly greater degree, forming particles that progressively grow, if Rh loading is about 0.75% or greater, whereas the Rh is effectively stabilized by the La 2 O 3 if the Rh loading is about 0.5% or less. This result is further illustrated by FIG. 2 , which plots surface Rh in micromoles per g as a function of time under cyclic aging for various Rh loadings and shows the stability of the 0.50% and 0.25% loading samples after the initial aging or “de-greening” period.
TABLE 3
Rh dispersion results (%) for 5% La/ZrO 2 catalysts with
varying amount of Rh after various periods of cyclic lean-rich aging
at 750° C.
# of steps
0 hrs
5 hrs
120 hrs
1% Rh
1
80
39
22
1% Rh
2
114
52
29
0.75% Rh
1
83
48
35
0.75% Rh
2
108
49
45
0.50% Rh
1
81
48
49
0.50% Rh
2
110
52
57
0.25% Rh
1
68
63
69
0.25% Rh
2
105
65
57
The values of Rh loading relate to concentrations of Rh on the surface of the refractory metal oxide. For the material used in these tests, 0.5% Rh loading corresponds to 0.005 g Rh per 100 m 2 surface area. Thus, the Rh loading is preferably about 5×10 −5 g/m 2 or less. Interpolation of the data suggests that an Rh loading of 3.5×10 −5 g/m 2 or less is even more preferable.
The preferred loading of rhodium can also be characterized by the Rh particles retaining at least about 40% dispersion, more preferably at least about 50% dispersion, after 400 hours of lean-rich cyclic aging at 750° C. The phenomenon by which Rh loses dispersion is sintering: the growth of Rh particles. According, yet another way to characterize the preferred loading of rhodium is that Rh loading at which the Rh average particle size remaining at about 2 nm or less after 400 hours of lean-rich cyclic aging at 750° C. through interaction with the La 2 O 3 coating. Particle size is defined as six times the particle volume divided by the particle surface area. This equation can be converted to an approximately correct equation to calculate Rh particle diameter in nm from Rh dispersion in percent: Rh particle diameter is about 100 nm divided by percent Rh dispersion. For example, the above case of a Rh catalyst with a dispersion of 50% has a particle diameter of about 2 nm.
Another of the inventors' concepts is to use La 2 O 3 in the same manner to stabilize a precious metal oxidation. Pd is the precious metal. Tests were conducted with Pt on a 14% La/Al 2 O 3 catalyst. Even 1% Pt added to 10% Pd caused a large degree of sintering. Accordingly, the precious metal of the oxidation catalysts preferably consists essentially of Pd.
A preferred refractory metal oxide for the oxidation catalyst is Al 2 O 3 . ZrO 2 and Si—Al 2 O 3 also gave acceptable performance to the extent they were tested, although higher dispersions were obtained with Al 2 O 3 then with ZrO 2 . Al 2 O 3 had a higher surface area than the ZrO 2 , the Al 2 O 3 being approximately 200 m 2 /g (170-230 m 2 /g), which is an additional advantage over ZrO 2 . Dispersion of Pd on Al 2 O 3 was improved slightly by impregnating the Pd as Pd(NH 3 ) 4 (NO 3 ) solution as compared to impregnating the Pd as palladium nitrate-nitric acid solution. Sintering occurred much more rapidly when Pd chloride solutions were used.
Table 4 show the effect of La surface loading on the dispersion of 5% Pd over ZrO 2 . 2.5% or more La significantly improved dispersion and dispersion stability on aging. Initial dispersions when the refractory metal oxide was Pd were higher, e.g., 22% for 5% Pd, 10% surface-deposited La, Al 2 O 3 . 5% La appears to be the minimum amount of surface La for a 200 m 2 /g alumina.
TABLE 4
Pd dispersion results (%) for 5% Pd/ZrO 2 catalysts with
varying amount of La after various periods of lean aging at
700° C. in 10% steam.
10 hrs
240 hrs
500 hrs
0% La
11%
7%
5.5%
2.5% La
19%
12%
11%
5.0% La
18%
13%
10%
7.5% La
19%
13%
11%
10% La
18%
13%
14%
A high concentration of active (surface) Pd is useful in promoting low temperature light-off. The more active Pd/g, the lower the light-off temperature. The amount of active Pd/g depends on the surface area of the catalyst, the Pd loading, and the dispersion of the loaded Pd. 100% dispersion would give about 940 μmoles Pd/g for a 10 wt % Pd loading.
Experiments showed that Pd dispersion on a molar basis increases linearly with Pd loading up to about 15% for a 10% surface-deposited La/Al 2 O 3 support, meaning that the dispersion remains constant on a percentage basis. Accordingly, the Pd loading is preferably at least about 10%, more preferably from about 15 to about 20%.
FIG. 3 shows the stability of 10% Pd co-dispersed with various amounts of La on a commercially available La-stabilized Al 2 O 3 support. The commercial product contained about 4% La, prior to impregnation with Pd and additional La. The plot shows stability through 1000 hours of lean aging with 10% steam. Dispersion improves with La loading up to about 10 or 15%. X-ray diffraction data showed no separate La phase, even through 20% loading. Accordingly, the La loading is preferably at least about a monolayer, more preferably at least about 10%, and still more preferably from about 15% to about 25%. 10% La corresponds to about 0.5 mg La per m 2 and 20% La to about 1.0 mg La per m 2 distributed over the surface of the refractory metal oxide particles.
A series of tests were conducted replacing all or part of the La with Nd. Nd is chemically similar to La. Like La, Nd has a stable 3 + charge. The tests showed that Nd is essentially fungible with La.
Other stabilizers were tested but did not show comparable advantages, either not improving dispersion, not improving stability, or interfering with catalyst activity. Sr in particular did not provided comparable performance to La. CeO 2 formed a separate phase on aging, which is undesirable in terms of maintaining dispersion. In addition, CeO 2 has substantial oxygen storage capacity, which is undesirable in this application.
The fuel reformer 104 typically has a metal or ceramic monolithic substrate comprising longitudinal channels through which the exhaust gas is designed to flow. The catalyst or catalysts can be applied as a washcoat layer on these channel walls. To apply the catalyst washcoat to the channel walls, a Pd—La—Al 2 O 3 or Rh—La—ZrO 2 catalyst powder such as described above can be mixed with water and other components and milled or attrited to form a sol or colloidal dispersion of small particles of the catalyst in water. This sol can then be coated onto the monolithic structure and the monolithic structure dried and heat treated to form a catalyst unit comprising the catalyst washcoat on the monolith walls. Many variations of this process are available. The sol can be prepared by adding solutions of La and precious metal to a slurry of refractory metal oxide powder in water that is then milled or attrited to form the small particle sol that is then coated onto the monolith. Alternatively, the La can be impregnated onto the refractory metal oxide, which is then dried and calcined. The resulting material can then be mixed with water and a precious metal solution and the slurry milled or attritted to form the final sol that is coated onto the monolithic structure, followed by drying and heat treating to from the final catalytic unit. To form a segmented catalyst with the oxidation catalyst coated on the inlet section and the reforming catalyst on the outlet section of the reformer 104 , the oxidation catalyst sol can be coated on an inlet section of monolith and the reforming catalyst sol can be coated on an outlet section of the monolith.
The invention as delineated by the following claims has been shown and/or described in terms of certain concepts, components, and features. While a particular component or feature may have been disclosed herein with respect to only one of several concepts or examples or in both broad and narrow terms, the components or features in their broad or narrow conceptions may be combined with one or more other components or features in their broad or narrow conceptions wherein such a combination would be recognized as logical by one of ordinary skill in the art. Also, this one specification may describe more than one invention and the following claims do not necessarily encompass every concept, aspect, embodiment, or example described herein. | 4y
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FIELD OF THE INVENTION
[0001] This invention relates generally to fluid controls and more particularly relates to a chemically inert fluid control module that may be connected in-line within a chemically corrosive fluid flow circuit that delivers fluids in either a liquid or gaseous state. The fluid control module of the present invention may be utilized to control the flow, pressure or volume of fluid flowing through the fluid flow circuit and is capable of automatically adjusting or “calibrating” the module to compensate for changes in atmospheric pressure or drift in the pressure sensors of the fluid control module.
BACKGROUND OF THE INVENTION
[0002] Caustic fluids are frequently used during ultra pure processing of sensitive materials. The susceptibility to contamination of the sensitive materials during the manufacturing process is a significant problem faced by manufacturers. Various manufacturing systems have been designed to reduce the contamination of the sensitive materials by foreign particles and vapors generated during the manufacturing process. The processing of the sensitive materials often involves direct contact with caustic fluids. Hence, it is critical that the caustic fluids are delivered to the processing site in an uncontaminated state and without foreign particulate. Various components of the processing equipment are commonly designed to reduce the amount of particulate generated and to isolate the processing chemicals from contaminating influences.
[0003] The processing equipment typically includes liquid transporting systems that carry the caustic chemicals from supply tanks through pumping and regulating stations and through the processing equipment itself. The liquid chemical transport systems, which includes pipes, tubing, monitoring devices, sensing devices, valves, fittings and related devices, are frequently made of plastics resistant to the deteriorating effects of the caustic chemicals. Metals, which are conventionally used in such monitoring devices, cannot reliably stand up to the corrosive environment for long periods of time. Hence, the monitoring and sensing devices must incorporate substitute materials or remain isolated from the caustic fluids.
[0004] The processing equipment commonly used in semiconductor manufacturing has one or more monitoring, valving, and sensing devices. These devices are typically connected in a closed loop feedback relationship and are used in monitoring and controlling the equipment. These monitoring and sensing devices must also be designed to eliminate any contamination that might be introduced.
[0005] In order to control the flow or pressure within the liquid transporting system, the transporting equipment may utilize information obtained from each of the monitoring, valving and sensing devices. The accuracy of the information obtained from each of the devices may be affected by thermal changes within the system. Further, the inaccuracy of one device may compound the inaccuracy of one of the other devices that depends upon information from the one device. Further, frequent independent calibration may be required to maintain the accuracy of each individual device, however, independent calibration of the devices may prove difficult and time consuming.
[0006] Hence, there is a need for a non-contaminating fluid control module which may be positioned in-line within a fluid flow circuit carrying corrosive materials, wherein the module is capable of determining the rate of flow based upon a pressure differential measurement taken in the fluid flow circuit, and wherein the determination of the rate of flow is not adversely affected by thermal changes within the fluid flow circuit, and wherein calibration of the pressure sensors of the fluid control module does not require ancillary or independent calibration of the valve. A need also exists for a fluid control module that avoids the introduction of particulate, unwanted ions, or vapors into the flow circuit. The present invention meets these and other needs that will become apparent from a review of the description of the present invention.
SUMMARY OF THE INVENTION
[0007] The present invention provides for a fluid control module that may be coupled in-line to a fluid flow circuit that transports corrosive fluids, where the fluid control module may determine pressure and flow rates and control the pressure, flow or volume within the fluid flow circuit. The rate of flow may be determined from a differential pressure measurement taken within the flow circuit. The fluid control module compensates for changes of temperature within the fluid flow circuit and provides a zeroing feature which compensates for differences in pressure when the fluid is at rest and negates the affects of the valve upon the system. In the preferred embodiment, the components of the fluid control module include a housing having a chemically inert fluid conduit, an adjustable control valve coupled to the conduit, pressure sensors coupled to the conduit, and a constriction disposed within the conduit having a reduced cross-sectional area to thereby restrict flow of fluid within the conduit and allow for reliable flow measurement. The chemically inert housing encloses the control valve and the pressure sensors.
[0008] When two pressure sensors are provided, the constriction is positioned between the two pressure sensors within the fluid flow conduit. As described in greater detail below, the fluid control module of the present invention having two pressure sensors provides for bidirectional fluid flow and may be coupled in line to adjacent ancillary equipment. In an alternate preferred embodiment, the fluid control module includes only one pressure sensor, wherein the constriction within the fluid conduit must be positioned downstream of the pressure sensor and valve. Also, the fluid control module having a single pressure sensor must be spaced apart a predetermined distance from ancillary equipment connected in line to the fluid flow circuit.
[0009] The drive or actuation of the control valve may be driven either mechanically, electrically or pneumatically by a driver having a known suitable construction and the valving components within the control valve may take on any of several suitable known configurations, including without limitation a poppet, diaphragm, redundant diaphragm, weir valve and/or pinch valve, wherein the components in direct contact with the fluid of the fluid flow circuit are constructed from chemically inert materials.
[0010] A controller or integrated circuit may be electrically coupled to the control valve and pressure sensor or sensors. The controller may produce a signal proportional to a fluid flow rate within the fluid conduit and/or a signal proportional to a pressure within the fluid conduit. The controller may control the pressure, rate of flow, or volume such that a desired set point is maintained. The set point may be defined by the user or automatically determined by the controller (for example, during a macro adjustment of the control valve). Further, the controller may adjust the fluid flow rate signal or pressure signal dependant upon changes in atmospheric or fluid pressure. Also, the controller may include a means for macro and micro adjustment of the control valve in response to changes in internal fluid or atmospheric pressure and may re-zero the pressure sensors when flow within the fluid flow circuit stops.
[0011] The housing that encloses the control valve and pressure sensors includes a bore extending therethrough, which forms a passage or conduit through which fluids flow, when the housing is connected in-line in a fluid flow circuit. Aligned and sealably connected to the opposed open ends of the bore are pressure fittings. The pressure fittings are constructed from a chemically inert material and are readily available and known to those skilled in the art.
[0012] In an embodiment of the present invention the housing has two pressure transducer receiving cavities extending from an external surface thereof, wherein each such cavity communicates independently with the bore. An isolation member may prevent the fluid flow from contacting the pressure transducer receiving cavities. The isolation members may be molded integral with the housing or may be removable. The bore tapers to a constricting region located between the two cavities. The restricted region results in a pressure drop within the bore across points adjacent the two cavities. This change in pressure may be detected by pressure sensor transducers placed within each of the two cavities. The rate of flow may be determined from the drop in pressure. The determination of the rate of flow using the two pressure sensors is described below in greater detail.
[0013] A hybrid or fully integrated electronic circuit disposed in the housing is operatively coupled to both pressure sensor transducers and the control valve. The electronic circuit develops a signal that is a measure of the rate of flow within the flow circuit from information sensed by the pressure sensors. Further, the electronic circuit may develop a signal corresponding to one or the other of the downstream or upstream static pressures within the fluid flow circuit, such that the orientation of the flow meter within the flow circuit is interchangeable and the direction of flow may be indicated by comparing the sensed pressure from each pressure sensor. When sensing the static pressures of gases flowing through the flow circuit, a correction may be made to the sensed pressures to correct for non-linearity and flow rates as a result of gas density and compressibility differences and effects.
[0014] This electronic circuit may also be used in combination with temperature sensitive components to adjust the pressure measurement associated with each cavity based upon temperature changes within the flow circuit. Further, the electronic circuit or controller may allow for zeroing of the pressure sensors and valve control. The electronic circuit is coupled by electrical leads to an electrical connector and power may be transmitted to the electronic circuit through the electrical leads connected to an external power supply. Further, an analog output such as a standard 4-20 milliamps signal, voltage output, or digital protocol proportional to the calculated rate of flow may be transmitted through additional electrical leads to a display or external controller.
[0015] The isolation membrane, pressure sensor, sealing members, spacer ring and hold down ring may be contained within each cavity of the housing. These components and variations thereof are described in greater detail in U.S. Pat. Nos. 5,869,766 and 5,852,244 which are assigned to the same assigns as the present application, the entire disclosure of which is incorporated herein by reference. In a further alternate embodiment, inert sapphire pressure transducers are positioned within respective cavities and in direct contact with the fluid flow, thereby eliminating the isolation membrane.
[0016] In use, the fluid control module is coupled in line to a fluid flow circuit. The pressure sensors may be pre-calibrated or the sensors may be calibrated at the time of interconnection with the fluid flow circuit. When calibrating the pressure sensors, the valve may be actuated between an open and closed position. When the pressure sensors indicate that flow has stopped, the output required to actuate the valve may be noted and thereby define an approximation of the closed position of the valve. Various set points may be identified to identify the valve position at various pressures, temperatures and flow rates. The calibration of a single pressure sensor will be described below in greater detail.
[0017] Once the flow meter is calibrated, the user may then select whether to control pressure, flow or volume within the fluid flow circuit. If pressure is controlled, the pressure and/or rate of flow is monitored and the valve is accordingly adjusted until a desired set point is reached. If flow is controlled, the pressure and/or flow is monitored and the valve is actuated until the desired set point is reached. The volume of fluid flowing through the fluid conduit may be controlled by monitoring both the pressure and rate of flow and accordingly adjusting the control valve to produce the desired volume of fluid flow. For example, the user may determine that 2 milliliters of fluid is desired. The valve is opened and the pressure and flow rates are monitored, such that it may be determined when 2 milliliters of fluid have passed through the module, wherein the control valve then closes terminating the fluid flow.
[0018] When flow is controlled, the controller may store in memory the output of the control valve driver required to obtain a certain flow. In this manner, when the user selects a desired flow, the controller sets the output of the driver approximately equal to an output that previously resulted in the desired flow rate (the macro adjust). Then controller may then manipulate or “fine tune” the control valve to precisely obtain the desired flow rate (the micro adjust). When the flow through the module is terminated by closing the control valve, the controller may then automatically adjust or re-zero the pressure sensors such that the difference between the measured pressures of the two pressure sensors is zero. In this manner, inaccuracy due to thermal changes and sensor drift is avoided. In an alternate preferred embodiment, a second valve is provided, wherein the second valve is a dedicated open/close valve. The output of the controller or electronic circuit may be delivered to an external controller or display.
[0019] The advantages of the present invention will become readily apparent to those skilled in the art from a review of the following detailed description of the preferred embodiment especially when considered in conjunction with the claims and accompanying drawings in which like numerals in the several views refer to corresponding parts.
DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a partial sectional side elevational view of the fluid control module of the present invention;
[0021] [0021]FIG. 2 is a partial sectional side elevational view of an alternate embodiment of the fluid control module of the present invention;
[0022] [0022]FIG. 3 is a partial sectional side elevational view of an alternate embodiment of the fluid control module of the present invention having a pneumatic actuated valve;
[0023] [0023]FIG. 4 is a partial sectional side elevational view of an alternate embodiment of the fluid control module of the present invention;
[0024] [0024]FIG. 5 is a partial sectional side elevational view of an alternate embodiment of the fluid control module of the present invention;
[0025] [0025]FIG. 6 is a partial sectional side elevational view of an alternate embodiment of the fluid control module of the present invention;
[0026] [0026]FIG. 7 is a partial sectional side elevational view of an alternate embodiment of the fluid control module of the present invention having a single pressure sensor;
[0027] [0027]FIG. 8 is a partial sectional side elevational view of an alternate embodiment of the fluid control module of the present invention having a single pressure sensor; and
[0028] [0028]FIG. 9 is a flowchart showing a sequence the controller may implement to control the fluid control module of the present invention.
DETAILED DESCRIPTION
[0029] The present invention represents broadly applicable improvements to chemically inert fluid controls. The embodiments detailed herein are intended to be taken as representative or exemplary of those in which the improvements of the invention may be incorporated and are not intended to be limiting. Referring first to FIG. 1 the fluid control module is generally identified by numeral 10 . The fluid control module 10 generally includes a rectangular housing consisting of a housing body 12 and housing cover 14 , mounting plate 16 , pressure inlet/outlet fittings 18 , pressure transducers 20 and control valve 22 . The housing body 12 and housing cover 14 are preferably manufactured from a chemically-inert, non-contaminating polymer such as polytetrafluoroethylene (PTFE). The cover 14 has bores 24 extending through it for mounting the cover 14 to the housing 12 with appropriate screws. A gasket of known suitable construction is preferably positioned between the cover and housing to allow the cover 14 to be sealed to the housing 12 . Without any limitation intended, a gasket or seal manufactured from a multi-layer fabric, sold under the GOR-TEX trademark by W. L. Gore & Assoc., Inc., allows venting of an internal area of the housing 12 for true atmospheric pressure reference, while restricting the flow of liquids into the internal area of the housing 12 .
[0030] A longitudinal bore 28 extends through the housing 12 forming a conduit. Thus, when the fluid control module 10 is connected in-line with a fluid flow circuit, via pressure fittings 18 , the bore 28 serves as the fluid flow passage within the fluid flow circuit. The orientation of the fluid control module 10 , within the fluid flow circuit, may be reversed without affecting its effectiveness. A constricting area 30 is formed in the bore 28 between the two pressure sensors 20 to create a pressure drop as the fluid flow traverses the constricting area or orifice 30 .
[0031] In the preferred embodiment, cylindrical cavities 32 extend from an outer surface of the housing 12 to the bore 28 . Those skilled in the art will appreciate that cavities 32 may each extend into the housing from different sidewalls of the housing. The two cavities 32 are separated a predetermined distance by dividing wall 34 . Near the region within the housing where each cavities 32 and bore 28 intersect, an annular lip 36 is formed. Each lip 36 surrounds and further defines the opening to each cavity 32 from the bore 28 . A thin flexible polymer disk or isolation membrane 38 is positioned on the lip 36 of each cavity 32 . Without limitation, the membrane is preferably constructed to have a thickness in a range between 0.001 and 0.040 inches. Preferably, the flexible membrane 38 is manufactured from fluorocarbon polymers. One such tetrafluoroethylene fluorocarbon polymer is sold under the TEFLON trademark by E. I. duPont Nemours. Alternatively, the isolation member 38 may be molded integral with the housing 12 to form a thin wall separating the cavity 32 and bore 28 .
[0032] Each pressure transducer 20 is held in place within their respective cavities 32 by spacer ring 48 and externally threaded hold down ring 50 . The isolation membranes 38 and transducers 20 are sealed within the housing 12 by chemically inert o-ring seals 52 . A redundant seal is created by the positioning of o-ring 54 . The seals 52 and 54 are readily available and of known construction to those skilled in the art.
[0033] A drain or conduit 40 may be formed extending through the housing 12 into each cavity 32 between the redundant seals 52 and 54 , thereby draining the area between the redundant seals. In this manner, the drain acts as a drainage, passageway or outlet, in the event that fluids leak past seal 52 from the fluid flow circuit. A sensor 42 may be positioned within the drain 40 and electrically connected (by leads not shown) to integrated circuit or controller 46 . Those skilled in the art will appreciate that a conductive sensor, capacitive sensor or non-electric fiber optic sensor may equally be used to sense the presence of fluids in the drain 40 . When fluid leaks past the first seal, the fluid activates the sensor 42 , thereby transmitting a signal to the electric circuit 46 which subsequently sets off a leak indicator. The redundant sealing arrangement helps prevent exposure of the pressure transducer 20 and controller 46 from the potential damaging affects of the caustic fluids. The redundant seal also further isolates the fluid flow, thereby reducing the potential contamination of the fluids.
[0034] Each pressure sensor 20 may be of a capacitance type or piezoresistive type known to those skilled in the art. The base of each pressure sensor is in direct contact with the membrane 38 and may be either in pressure contact with or bonded to the membrane by an adhesive, thermal welding or by other known suitable fixation. In an alternate embodiment, an alumina ceramic pressure sensor may be used, wherein the alumina ceramic pressure sensor comprises a thin, generally compliant ceramic sheet having an insulating spacer ring sandwiched between a thicker, non-compliant ceramic sheet. The first thin ceramic sheet or diaphragm is approximately 0.005 to 0.050 inches in thickness with a typical thickness of 0.020 inches. The thicker ceramic sheet has a thickness range between 0.100 to 0.400 inches. The spacer ring may be constructed of a suitable material such as a glass, polymer or alternatively the ceramic sheets may be brazed together. The opposed faces of ceramic disks are metalized by metals such as gold, nickel or chrome to create plates of a capacitor. A similar capacitive pressure transducer is described by Bell et al. in U.S. Pat. No. 4,177,496 (the '496 patent). Other capacitive pressure transducers similar to that described in the '496 patent are available and known in the art. It is contemplated that the flexible membrane 38 could be eliminated if the pressure sensor used is of the sapphire capacitive pressure transducer type. A sapphire capacitive or sapphire piezoresistive transducer type is inert, and is resistant to wear when subjected to caustic fluids. Having a sapphire sensor in direct communication with the fluid flow may further enhance the pressure measurements of each transducer.
[0035] The controller 46 may be in any of several forms including a dedicated state device or a microprocessor with code, and may include Read Only Memory (ROM) for storing programs to be executed by the controller and Random Access Memory (RAM) for storing operands used in carrying out the computations by the controller. The controller 46 is electrically coupled to a power supply and manipulates the electrical circuitry for sensing pressure and controlling the actuation of the control valve, wherein flow, pressure and/or volume may be controlled.
[0036] The controller 46 is used to convert the pressure readings from the two pressure transducers 42 and 44 to an analog or digital representation of flow or, alternatively, a pressure reading of the downstream pressure transducer. The raw analog signal from the upstream transducer is supplied to an input terminal and, likewise, the raw analog transducer output signal from the downstream transducer is supplied to an input terminal. The controller 46 computes the instantaneous pressure differences being picked up by the upstream and downstream transducers and performs any necessary zeroing adjustments and scaling.
[0037] It is known that, in steady-state flow, the flow rate is the same at any point. The flow rate (I) may be expressed as I m =ρvA. Where ρ represents the density of the fluid, v represents the velocity of the fluid, and A represents the area through which the fluid travels. Using the continuity equation A 1 v 1 =A 2 v 2 , the rate of flow within the fluid control module 10 may be found equal to a constant multiplied by {square root}{square root over (P 1 −P)} 2 . The controller 46 thus computes the pressure and rate of flow from the data received from the two pressure sensors. Those skilled in the art will recognize that with laminar flow, the rate of flow approximates more closely a constant multiplied by P 1 −P 2 . Hence, a low flow limit could be built into the system, such that if the “Reynolds number” is below a certain threshold, the flow meter identifies the flow rate as zero. The controller 46 may then convert the computed rate of flow into a digital signal or an analog signal falling in the range of from 4 mA to 20 mA for use by existing control systems.
[0038] As fluid flows through the flow circuit, the pressure adjacent each of the two cavities is detected by the controller 46 , whereby the rate of flow may be calculated from the two detected pressures. The gauge pressure or absolute pressure may equally be used. Those skilled in the art will recognize that the flow rate may be calibrated so that minimum desired output values are associated with minimum pressure and maximum desired output pressures are associated with maximum pressure. For example, a pressure sensor intended to measure 0 to 100 psig (pounds per square inch gauge) can be calibrated to read 4 mA (milliamps) at 0 psig and 20 mA at 100 psig.
[0039] The conduit 28 interconnects with the control valve 22 , wherein a valve seat 60 is formed within the fluid conduit. A double diaphragm 62 is actuated fore and aft, wherein when the diaphragm is actuated into engagement with the valve seat 60 , fluid flow past the valve seat is terminated. Alternatively, a single diaphragm may be utilized to control the flow of fluid past the valve seat 60 (see FIG. 2). Those skilled in the art will appreciate that the double diaphragm 62 is unaffected by changes in atmospheric pressure. The driver 66 shown in FIG. 1 used to actuate the diaphragm 62 is of the electric motor type. Those skilled in the art will appreciate that the actuation of the valve between the open and closed position may be accomplished with any of several mechanical electrical or pneumatic drivers of known suitable construction. Further, without limitation, the mechanism for opening and closing flow may comprise for example, a diaphragm, poppet, weir valve, or pinch valve with the diaphragm and valve seat being preferred.
[0040] [0040]FIG. 3 illustrates an alternate embodiment of the driver 66 being of the pneumatic type. A piston 68 is sealed within a sealed chamber 70 , wherein the mechanical force of a compression spring 72 forces the piston 68 in a downward or first direction and a pressurized air line 74 increases the pressure on the lower end 76 of the piston to force the piston 68 upward thereby compressing the spring 72 . In this manner, the air pressure within the chamber 70 may be increased or decreased a controlled amount to actuate the piston 68 and thus the diaphragm 64 attached to the piston 68 between an open and closed position. The lower end of the diaphragm 64 may include a conical member 78 extending therefrom which may enhance the sealing between the valve seat 60 and the diaphragm 64 (see FIG. 4). Alternatively, a valve stem 80 extending from the piston 68 may extend through the chamber wall 82 through a bore 82 having a seal 84 to seal the air chamber 70 and provide for fore and aft motion of the valve stem 80 within the bore 82 (see FIG. 5). The lower end 86 of the valve stem 80 seals directly with the valve seat 60 when in the closed position. The lower end 86 may be tapered to further enhance the sealing between the valve stem 80 and the valve seat 60 when in the closed position (see FIG. 6).
[0041] Referring to FIGS. 7 and 8 alternate embodiments of the fluid control module 10 are shown having a single pressure sensor for determining flow rates within the fluid flow conduit. The control valve 22 shown in FIG. 7 is pneumatically driven as described above in greater detail. The control valve 22 shown in FIG. 8 is actuated by the motor 66 as described above in greater detail. When determining flow rates with the fluid control module of the type shown in FIGS. 7 and 8, the orifice 30 must be downstream of the pressure sensor 20 and control valve 22 and the output end 90 of the fluid control module 10 must be connected to a conduit, tubing, void, or other pathway wherein the pressure therein is at atmospheric pressure (a known constant). In this manner the flow rate may be determined as described above, wherein the pressure P on the downstream side of the orifice is a constant. Additionally, a tubing of known length and diameter may be coupled to the output end 90 of the fluid control module 10 , whereby the pressure difference between the pressure at the output end 90 and the pressure within the tubing is constant. In use, the tubing may be filled with fluid and then the control valve 22 may be shut. The pressure sensor is then calibrated to indicate zero pressure. When the control valve is opened, then the pressure sensor will indicate the change in pressure.
[0042] Having described the constructional features of the present invention the mode of use in conjunction with FIG. 9 will next be described. The controller 46 either automatically or when prompted by the user calibrates the pressure sensors 20 and control valve 22 (see block 100 ). During the calibration process, the controller creates and stores in memory values corresponding to valve position, flow rate and internal and external pressure for predetermined set points. Once the valve position, flow and pressure are known for desired set points, the controller may automatically set the valve position based on determined flow pressure or demand by the external process. Alternatively, the user may select a desired set point and the controller adjusts the valve position based on measured pressure and flow rates (see block 102 ). The controller then determines whether it is desired to control pressure (see decision block 104 ). If pressure is to be controlled, the controller monitors the pressure and/or flow rate and adjusts the valve to keep the pressure at a controlled amount (see block 106 ). If it is not desired to control pressure, the controller then determines whether it is desired to control flow (see decision block 108 ). If flow is to be controlled, the controller monitors pressure and/or flow and adjusts the valve to keep the flow rate at a controlled amount (see block 110 ).
[0043] The control may include a macro and micro adjust of the control valve, wherein the controller stores values associated with flow rate, pressure, temperature and valve position for the set points. When the flow, for example, is controlled the controller adjusts the valve to roughly approximate the valve position for prior measured pressure temperature and valve position for the desired flow (the macro adjust). Thus, the flow rate may be approximated rather quickly and then the control may make minor adjustments to the valve position to obtain an even more precise control of flow (see block 112 ). If volume is to be controlled (see decision block 114 ) then the flow rate and pressure are monitored and the valve is opened for a time sufficient to allow the controlled volume of fluid to pass past the control valve 22 (see block 116 ). If neither the pressure, flow or volume is to be controlled then the controller waits to receive input (see loop 118 and block 102 ).
[0044] During fluid processing, the controller 46 may automatically re-zero or calibrate the pressure sensors when the control valve 22 is closed (see block 120 ). Alternatively, a second dedicated valve may be provided which is operable in either an open or closed position. The controller may be programmed to re-zero the pressure sensors when the second dedicated valve is in the closed position. During processing, the pressure within the flow conduit may undergo significant changes, thereby requiring changes in the valve position to keep the flow rate, for example, constant (see block 122 ). The controller 46 waits to receive the next input (see loop 124 and block 102 ). Thus, the control module of the present invention eliminates the additional components and disadvantages of interconnecting individual pressure sensors and individual control valves.
[0045] This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself. | 4y
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FIELD OF INVENTION
The present invention relates to power converters, and more particularly, to a circuit that controls synchronous rectifier back bias in non-isolated DC-DC buck converters.
BACKGROUND OF THE INVENTION
Increasingly, synchronous rectifiers are replacing freewheeling diodes in non-isolated DC-DC buck converters in order to increase the power conversion efficiency of the converters. One feature of non-isolated DC-DC converters with synchronous rectification is that current is enabled to flow not only to the output terminals through the synchronous rectifier but also in a reverse direction from the output terminals back into the converter, i.e., a non-isolated dc-dc converter with synchronous rectification can have both current-sourcing and current-sinking capability.
A conventional buck converter is shown in FIG. 1 . As is well known, a basic buck converter comprises a switch 6 , an input filter capacitor 8 , a freewheeling diode 12 , an inductor 14 , and a capacitor 16 , connected in a conventional way between an input terminal 2 to which is coupled an input voltage V in relative to ground, and an output terminal 22 at which the buck converter generates a regulated output voltage V o relative to ground. An exemplary load 20 is shown coupled to the output of converter 10 . The switch 6 is typically an electronic switch, such as a MOSFET, that is controlled in a known manner by a control circuit, e.g., a pulse width modulator (PWM) (not shown in FIG. 1 ) that is responsive to the output voltage V o . When the switch 6 is closed, the capacitor 16 is charged via switch 6 and inductor 14 from the input voltage V in to produce the output voltage V o , which is consequently less than the peak input voltage V in . When switch 6 is open, current through the inductor 14 , identified as I o , is maintained via diode 12 .
In order to boost power conversion efficiency, the freewheeling diode 12 is preferably replaced with a MOSFET, defined as a synchronous rectifier, identified as 18 in FIG. 1 and shown connected using dotted lines. In operation, synchronous rectifier 18 lowers the voltage drop across nodes 7 and 5 that otherwise exists with diode 12 . Only uni-directional current flow is permitted through the freewheeling diode 12 . By contrast, the synchronous rectifier 18 permits bi-directional current flow. As a result, inductor current, I o , can flow in reverse through synchronous rectifier 18 from the output. Synchronous rectifier 18 is preferably controlled directly by a PWM (not shown). Although switch 6 and synchronous rectifier 18 are both driven by a PWM, it is well known that the control signals from the PWM for these elements are complementary signals such that switch 6 and synchronous rectifier 18 are never turned on at the same time, in order to prevent the shorting of the input terminal 2 to ground.
The bi-directional current flowing capability of the synchronous rectifier 18 may pose a serious problem when such rectifiers are used in paralleled power converters. The paralleling of power converters provides a way for two or more individual, small, high density power converter modules to supply the higher power required by current generation loads and/or to provide redundancy. Applications may also require various configurations of paralleled converters. A known application, e.g., for a digital signal processor, requires paralleled converters to be configured for sequential operation, wherein the converters are powered on sequentially according to a predetermined sequence. FIG. 2 is a block diagram of a prior art system having two paralleled power modules connected in a sequencing configuration to supply power to two loads. The parallel sequencing system 30 in FIG. 2 includes a converter 32 connected in parallel with a converter 34 . According to the sequencing for an embodiment of system 30 , converter 32 is always turned on before converter 34 is turned on. Each converter 32 , 34 is a buck converter having a synchronous rectifier in place of the freewheeling diode, as shown in FIG. 1 . As shown in FIG. 2 , power is supplied to converters 32 , 34 from a single power input, V in , at input terminals 2 , 4 . It will be recognized by those skilled in the art that it is not necessary that power be supplied to the converter at a single power input port. Rather, each power module may receive power from a separate power source such as separate AC-DC converters (not shown). Converter 32 is coupled to output terminals 42 and 44 to supply an output voltage V A0 to a load, shown schematically as 28 . Converter 34 is coupled to output terminals 38 , 40 to supply an output voltage V B0 to a load, shown schematically as 26 . The output of each converter 32 , 34 is also coupled to the output terminals of the other converter via a diode 36 . Diode 36 has an anode coupled to output terminal 42 of converter 32 and a cathode coupled to the output terminal 38 of converter 34 . The corresponding negative output terminals 44 , 40 of each converter are also connected as shown in FIG. 2 .
In operation, converter 32 is turned on first while converter 34 remains off. During this time, the synchronous rectifier in converter 34 remains in an off state. At this time, converter 32 supplies an output voltage V A0 to a load 28 . However, since converter 34 is off, diode 36 is in a conduction state. As a result, converter 32 also provides power to a load 26 . At this point in the sequence, converter 34 is turned on. As converter 34 begins to operate, its synchronous rectifier, now turned on, will pull down the paralleled outputs to a level corresponding to the programmed soft-start level for converter 34 . This pulling-down effect causes a short circuit operation of converter 32 during the soft-start period for converter 34 . This effect is one example of an effect commonly referred to as the “synchronous rectifier back bias” problem of non-isolated dc-dc buck converters. The synchronous rectifier of converter 34 will continue this “pulling-down” effect until the output voltage of converter 34 becomes equal to the output voltage of converter 32 , at which point diode 36 no longer conducts and the two converter outputs become uncoupled from one another. In practice, a short circuit protection will be triggered and the system 30 cannot remain in operation without special attention. A need therefore exists for overcoming this synchronous rectifier back bias problem for the system of FIG. 2 , while having the benefits provided by the use of a synchronous rectifier, namely reduced cost and higher density, as demanded for modern devices.
FIG. 3 is a block diagram of another configuration of a system of parallel converters (also referred to herein as “power modules”). For the paralleled converter configuration shown in FIG. 3 , power is supplied to a common output voltage bus and thereby to a load. As shown in FIG. 3 , power module 1 , power module 2 , . . . power module N are each coupled to a single power output port 320 for supplying power to a load. An exemplary load 330 is shown coupled to output port 320 of system 300 . In a preferred embodiment, power is supplied to power modules 1 through N at a single power input port 340 . It will be recognized by those skilled in the art that it is not necessary that power be supplied to power modules 1 through N at a single power input port. Rather, each power module may receive power from a separate power source such as separate AC-DC converters (not shown).
In one exemplary system, the power modules 1 through N are buck converters having a synchronous rectifier in place of the freewheeling diode, as shown in FIG. 1 . For this exemplary system, because the synchronous rectifier allows reverse current flow, a system failure may result, e.g. from recycling one or more modules while the system is already in operation, and powering on each of paralleled modules at different times, etc.
A need therefore exists for a circuit that actively and efficiently controls the synchronous rectifier in the respective power converters in a system having paralleled power converters in order to eliminate the synchronous rectifier back bias problem. There is also a need for a circuit that provides this function during the soft start period of a power converter in a paralleled converter configuration.
SUMMARY OF THE INVENTION
The present invention solves the problems of prior art devices by providing, in a system comprising a plurality of paralleled converters, a control circuit that efficiently prevents the turning on of the synchronous rectifier in a buck converter during a predetermined condition, so as to prevent current reversing through the synchronous rectifier during that time. In one embodiment, the present invention provides control of the synchronous rectifier during the soft-start time for a non-isolated DC-DC buck converter, thereby preventing current reversing (sinking) during its soft start process. In another embodiment of the present invention, a circuit uses a signal indicative of a soft-start condition for a converter to prevent the turning on of the synchronous rectifier during the soft-start time. The present invention also solves the synchronous rectifier back bias problem during the soft-start of a converter used in a paralleled converter configuration.
Consequently, embodiments of the present invention have the advantage of preventing the synchronous rectifier back bias problem and doing so at reduced cost using fewer components than known devices.
Broadly stated, the present invention provides, in a system having a buck converter comprising a switch, an inductor, a capacitor and a synchronous rectifier, the buck converter having two input terminals to which an input DC voltage is coupled and two output terminals where the output DC voltage is provided, the synchronous rectifier having a control input and being controlled such that when the switch is open, current through the inductor is maintained by a path provided by the synchronous rectifier, and having a pulse width modulator (PWM) having an output designed to provide control of the state of the synchronous rectifier; a control circuit coupled between the PWM output and the control input of said synchronous rectifier for controlling the synchronous rectifier during a predetermined condition, comprising a comparator circuit for comparing a feedback signal indicative of the predetermined condition to a predetermined reference voltage, such that said comparator circuit outputs a control signal when the predetermined condition is active; a driver circuit responsive to the control signal to turn off the synchronous rectifier when the predetermined condition is active so as to prevent the PWM from controlling the state of the synchronous rectifier and so as to enable the PWM to control the synchronous rectifier when said predetermined condition is not active.
Broadly stated the present invention also provides, a power system having a plurality of DC-DC converter modules, each having an input terminal to which an input DC voltage is coupled and an output terminal where the output DC voltage is provided, said converter modules being connected in parallel through their output terminals to a common bus connected to a load, each said converter module comprising: a buck converter for converting said input DC voltage to a regulated output DC voltage, said buck converter having a switch and an inductor connected in series between its respective input terminal and output terminal, said inductor having one end connected to its respective output terminal, a synchronous rectifier connected between said other end of said inductor and ground, and a capacitor connected between its respective output terminal and ground; a pulse width modulator (PWM) having an output designed to provide control of the state of said synchronous rectifier; a control circuit coupled between said PWM output and said control input of said synchronous rectifier for controlling said synchronous rectifier during a predetermined condition, comprising: a comparator circuit for comparing a feedback signal indicative of said predetermined condition to a predetermined reference voltage, such that said comparator circuit outputs a control signal when said predetermined condition is active; and a driver circuit responsive to said control signal to turn off said synchronous rectifier when said predetermined condition is active so as to prevent said PWM from controlling the state of said synchronous rectifier and so as to enable said PWM to control said synchronous rectifier when said predetermined condition is not active.
BRIEF DESCRIPTION OF THE DRAWINGS
The forgoing aspects and the attendant advantages of the present invention will become more readily appreciated by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 illustrates a typical prior art non-isolated DC-DC buck converter;
FIG. 2 is a block diagram of a prior art system having two power modules connected in a sequencing configuration to supply power to separate loads;
FIG. 3 is a block diagram of a prior art system of power modules connected in parallel through their output terminals to a common bus connected to a load;
FIG. 4 shows an embodiment of the circuit according to the present invention for use in a system that does not provide a signal indicative of the soft-start condition; and
FIG. 5 shows a preferred embodiment of the circuit according to the present invention for a system having an accessible soft-start indication.
DETAILED DESCRIPTION OF THE INVENTION
The present invention overcomes the drawbacks of known prior art circuits. A preferred embodiment of the circuit for each converter in a paralleled system of converters is shown in FIG. 5 . The converter 200 has an input terminal 104 to which an input DC voltage V in is coupled relative to ground and an output terminal 122 where the output DC voltage V O of each converter module is provided relative to ground. Converter 200 includes a control circuit 250 coupled to a buck regulator 102 having a synchronous rectifier 118 . The buck regulator 102 comprises a switch 106 , an inductor 114 , and a capacitor 116 , connected in a conventional way between input terminal 104 and output terminal 122 . An exemplary load R L is shown coupled to the output of converter 200 . Switch 106 is typically a power MOSFET which is controlled in a known manner by a PWM 166 that is responsive to the output voltage V o . When the switch 106 is closed, the capacitor 116 is charged via switch 106 and inductor 114 from the input voltage to produce the output voltage V o , which is consequently less than the peak input voltage. When switch 106 is open, current through the inductor 114 is maintained via synchronous rectifier 118 .
In buck regulator 102 , the synchronous rectifier 118 replaces a conventional freewheeling diode, as is shown in FIG. 1 , in order to boost power conversion efficiency. Synchronous rectifier 118 has a control input and is preferably a MOSFET whose control input is the gate of the MOSFET. The synchronous rectifier 118 permits bi-directional current flow. As a result, the inductor current can flow in reverse through synchronous rectifier 118 from the output. The synchronous rectifier 118 is conventionally controlled directly by a pulse width modulator PWM 146 . Switch 106 and synchronous rectifier 118 may be driven by the same pulse width modulator. It is well known conventionally that the control signals from the pulse width modulator for the control inputs of switch 106 and synchronous rectifier 118 must be complementary signals such that both devices are not turned on at the same time, so as to avoid shorting the input terminal 104 to ground. As seen in FIG. 5 , for converter 200 , however, a control circuit 250 is coupled between a PWM 146 and the gate input of the synchronous rectifier 118 . Thus, for the present invention, a PWM is not directly coupled to the control input of the synchronous rectifier 118 . According to the embodiment of the present invention shown in FIG. 5 , control circuit 250 provides direct control of the on and off state of synchronous rectifier 118 .
Control circuit 250 includes a comparator circuit 204 coupled to a driver circuit 170 that is coupled directly to the gate input of synchronous rectifier 118 . The driver circuit 170 comprises a PNP transistor 120 , an NPN transistor 130 , and a resistor 126 . Transistor 120 has a base and collector, both coupled to PWM 146 at node 125 , and an emitter coupled to the control input of synchronous rectifier 118 . Transistor 130 has a collector coupled to PWM 146 at node 125 , an emitter coupled to the control input of synchronous rectifier 118 , and a base coupled through resistor 126 to node 125 . The base of transistor 130 is also coupled to the comparator circuit 104 at a node 135 .
Comparator circuit 204 includes a transistor 128 . Transistor 128 is shown as an NPN transistor in FIG. 5 . Transistor 128 is preferably a bipolar transistor type. As shown in FIG. 5 , transistor 128 has a collector connected to node 135 , an emitter coupled to ground, and a base. The base of transistor 128 is coupled to the output of a comparator 110 .
The comparator 110 has a positive input and a negative input. A reference signal 236 is coupled to the positive input of comparator 110 . The reference signal 236 is preferably generated by a conventional voltage divider circuit coupled to a voltage reference V ref . The voltage divider is preferably formed by a resistor 142 and a resistor 144 connected in series between V ref and ground.
For the preferred embodiment of the circuit of the present invention shown in FIG. 5 , a soft-start indication signal 210 is fed back to the negative input of comparator 110 in control circuit 250 . The soft-start indication signal 210 is preferably provided by PWM 146 . As described above with reference to FIG. 2 , it is during the soft-start period of the buck converter when the synchronous rectifier back bias problem is experienced. Thus, preferably a signal indicative of this soft-start period is used by the control circuit of the present invention to eliminate this problem. Once the soft-start sequence is completed, and the buck converter is outputing the required output voltage for normal operation, the soft-start indication signal is not longer active.
The operation of the converter 200 will now be described in further detail. During the soft-start period of the buck converter 102 , control circuit 250 operates to block the PWM from controlling the synchronous rectifier 118 . When the buck converter 102 is not in the soft-start period, control circuit 250 enables the PWM to control the synchronous rectifier 118 of the buck converter 102 .
For the embodiment in FIG. 5 , comparator 110 compares the soft-start indication signal 210 to the reference signal 236 . During the soft-start period, signal 210 is active. Preferably, the reference signal 236 is set to a predetermined level such that signal 236 is higher than the level of the soft-start indication signal 210 when the converter is in soft-start mode, and reference signal 236 is not higher than the soft-start signal when the converter is not in soft-start mode. As a result, comparator 110 outputs a “high” signal during the soft-start period of the converter, and a “low” signal otherwise.
Thus, during soft-start mode of the converter, comparator 110 sets the base of transistor 128 high, thereby causing transistor 128 to switch to a conductive state. During this conductive state, because the emitter is coupled to ground, the voltage at the collector of transistor 128 is also pulled down to a low voltage level near ground. The base of transistor 130 at node 135 is coupled to the collector of transistor 128 , and so is also pulled down to a low voltage level near ground. As a result, transistor 130 is nonconductive.
Conventionally, the PWM outputs a high level signal, preferably 5V, at signal line 138 in order to set the synchronous rectifier 118 in an “on” conductive state. When transistor 130 is non-conductive, it prevents signal 138 from being coupled to the control input of the synchronous rectifier.
Transistor 120 is a PNP transistor having a base and collector connected to the PWM at node 125 , and an emitter connected to the control input of the synchronous rectifier 118 . Thus, transistor 120 does not provide a path for the PWM 146 to set the control input of the synchronous rectifier 118 . As a result, during the soft-start period of the buck converter 102 , the circuit of the present invention blocks PWM 146 from controlling the synchronous rectifier 118 . If the synchronous rectifier 118 was on during the soft-start period, transistor 120 functions to turn synchronous rectifier 118 off by discharging the gate charge at the its control input. Control circuit 250 holds synchronous rectifier 118 in the off state until the soft-start indication signal 210 indicates the converter is no longer in soft-start.
When the converter is not in soft-start mode, the output of comparator 110 is low, the base of transistor 128 is low, making transistor 128 non-conductive. This causes the collector of 128 to present a floating level to the base of transistor 130 at node 135 . As a result, driver circuit 170 no longer blocks the PWM from the control input of the synchronous rectifier 118 , thereby allowing the PWM to control the state of the synchronous rectifier 118 . Thus, during the soft-start period the control circuit 250 turns off synchronous rectifier 118 and keep it off during this period, thereby preventing reverse current flow through the synchronous rectifier 118 and solving the back bias problem.
FIG. 4 shows an alternate embodiment of the circuit according to the present invention for use for a system that does not provide a signal indicative of the soft-start condition. As seen in FIG. 4 , the converter 100 differs from the embodiment in FIG. 5 , since in FIG. 4 , the output voltage at terminal 122 is fed back for comparison to a reference by comparator 110 rather than a soft-start indication signal. For converter 100 , a suitable reference signal 136 is provided by a voltage divider circuit formed by a resistor 132 and 134 in order to output a signal from comparator 110 , such that the comparator output is active during the soft-start period.
For another alternate embodiment, any suitable signal can be fed back to the control circuit 250 , in order to disable the synchronous rectifier 118 during a predetermined condition.
According to another embodiment, the present invention provides a system that solves the aforementioned synchronous rectifier back bias problem for a converter used in a paralleled converter configuration, wherein each converter corresponds to converter 100 in FIG. 4 . Two embodiments of the paralleled configuration of converters are shown in FIGS. 2 and 3 . Alternately, the present invention provides a system of paralleled converters wherein each converter corresponds to converter 200 in FIG. 5
The foregoing detailed description of the invention has been provided for the purposes of illustration and description. Although exemplary embodiments of the present invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to the precise embodiments disclosed, and that various changes and modifications to the present invention are possible in light of the above teaching. | 4y
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This application is a continuation of application Ser. No. 369,863, filed Apr. 19, 1982, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to metallized fabrics, particularly for use in ironing board covers and the like which are copper coated and therefore highly heat retentive and heat reflective, as well as highly scorch resistant.
Traditionally, ironing board covers have been made of natural loom-state greige cotton fabric. In later years, this fabric was either bleached white, dyed or screen printed. This later evolved into fabric with a super-imposed coating in the form of a continuous metal film overlying the fabric surface. Such coatings include pure aluminum flakes, teflon or silicone, and other materials dispersed in acrylic resin binders.
Metallized ironing board covers are described in U.S. Pat. Nos. 2,600,913 and 3,049,826. In each case, the metallized layer overlying the upper surface of the cover fabric is in the form of a continuous film, which is integral, non-porous and smooth. In each case, the surface characteristics of the ironing board cover are those of the metal film.
Metallized fabrics are also known and are described, for example, in U.S. Pat. No. 4,032,681. This patent describes a reflective fabric comprising a base fabric covered with a metal film bonded to the fabric. The metal film is fractured to provide openings in the film to let the fabric "breathe", but the surface characteristics of the finished product are still those of the metal film.
Known metallized ironing board covers and other metallized fabrics often use aluminum as the metal. This is yet another drawback to known metallized fabrics because, in producing aluminum coated ironing board covers, there is a danger of hydrogen gas build-up in the sealed drums or areas where the aluminum is mixed with water.
In recent times, there has been an acute interest in energy saving both from a labor and time saving viewpoint, as well as in terms of saving electricity. The aluminized coated ironing board covers are generally satisfactory due to their heat reflective property, but there is a need for an ironing board cover that is not only heat reflective, but heat retentive so as to save labor and electrical energy. The present invention concerns the accomplishment of these goals during the ironing and pressing of cloth articles and the like. Furthermore, the present invention does not involve the hazards of working with potentially dangerous aluminum solutions.
It is also an object of the present invention to provide a metallized fabric in which the metallized surface of the fabric substantially retains the characteristics of the fabric. That is, in known metallized fabrics, the surface characteristics are those of the overlying metal, whereas with the present invention, the texture, porosity and flexibility of the surface are substantially those of the fabric. This novel result is achieved by the manner in which the metal coating is applied to the fabric, as described more fully hereinafter. This result is significant in that it provides a metallized fabric which is heat-reflective and heat-retentive, yet substantially possesses the surface characteristics of fabric rather than of metal. This provides the texture, flexibility and porosity necessary for proper ironing. That is, the fabric surface texture provides friction which assists in holding in place the article to be ironed, while the fabric porosity enables steam and moisture to pass through the fabric to the underlying pad which permits the article to be ironed dry in fewer ironing strokes. These properties are not achieved in known metallized fabrics.
SUMMARY OF THE INVENTION
The present invention relates to a metallized fabric, in particular, a cover for an ironing board or a pressing machine. The fabric is a cotton containing fabric which is coated at least on its upper exposed surface with a coating comprising a metallic component containing at least 85 weight percent copper. In a preferred embodiment, the metallic component itself is coated with a non-metallic component such as a silicate or silicone oxide.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there are shown in the drawings froms which are presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a perspective view of an ironing board whose ironing surface is covered with an ironing board cover in accordance with the present invention.
FIG. 2 is an exploded isometric view depicting an ironing board cover in accordance with this invention in conjunction with an ironing surface of an ironing board.
FIG. 3 is a partial sectional view taken along the line 3--3 of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings in detail, wherein like numerals indicate like elements, there is shown in FIG. 1 an ironing board 10 having an upper ironing surface 12. Overlaying the upper ironing surface 12 is an ironing board cover 14. The ironing board cover 14 is composed of a layer of coated fabric 16 which has the general outline of a typical ironing board 10, but its edges 18 extend past the edges 20 of the ironing board surface 12.
The fabric 16 can be a woven, knitted, or non-woven fabric of cotton or blends thereof. At least the upper surface of the fabric 16 is coated with a copper containing component. The copper content of the metallic coating component is at least 85 weight percent, and is preferably at least 99 weight percent. Besides copper, the metallic component may contain zinc, tin, or both zinc and tin.
The metallic component is generally in the form of fine particles, i.e., a powder, or flakes. The micron size of the metallic particles is between about 5 microns and about 48 microns.
The metallic component particles are themselves coated with a non-metallic component such as silicates or silicone oxide. This non-metallic coating serves to insure that the ultimate coating will not tarnish from exposure to heat or the atmosphere.
The ultimate coating can be applied to the fabric material with the coating in solution form. The solvent can be aqueous or non-aqueous. A non-ionic acrylic binder is utilized with the ultimate coating. The coating can be applied to the fabric by any convenient method such as by using a knife coater, roller coater, flat bed screen printer, rotary screen printer, or unit printer.
The resultant coated fabric is porous, scorch-resistant and stain resistant, and substantially retains its fabric surface texture, flexibility and porosity. The printing process coats the fabric fibers on the fabric surface and, because of the printing pressure inherent in the printing process, coats the fibers for a region below the surface, but does not form a continuous film of metal as in known metallized fabrics. Rather, the printing process allows the fabric pores to remain open. This results in the finished fabric being porous and flexible and retaining its fabric surface texture. The resultant fabric also has a dual action property. The metallic coated surface reflects heat more efficiently than conventional ironing board covers because the natural super conductive quality of copper retains the heat that radiates into it from the heated soleplate of the iron. In the case of the purely heat reflective aluminized ironing board cover, heat is only reflected while the heated iron is positioned directly over the given contact area, and is dissipated into the atmosphere once the iron has been stroked past the given area. In the case of the combination heat retaining and heat reflective coppered ironing board cover of the present invention, heat is stored on the surface of the ironing board cover and in the coated region below the surface and is therefore generated not only when the iron is directly over the given contact area, but even when the iron has been stroked past the given area. Since repeated back-and-forth ironing strokes are required in the ironing process to drive out the dampness and the wrinkles from the article being ironed, the fact that the ironing surface in contact with the iron maintains and reflects heat means that significantly fewer ironing strokes are required. This would be somewhat analogous to a commercial pressing machine with a dual steam or electrically heated head and back.
Since another property of the copper coated ironing board cover of this invention is to distribute heat evenly, the coated fabric is substantially more scorch resistant because it is less affected by heat deterioration from hot spots.
The resultant reduction in ironing strokes by use of the ironing board cover of the present invention reduces heat exposure and abrasion on both the ironed article and the ironing board cover proper thus realizing extended life and wear in both. The higher level of ironing heat means that in the case of dry ironing, the temperature setting of the iron can be reduced lower than the previous norm. This results in a savings of electricity.
The edges 18 of the layer of fabric 16 may have binding or welting 22 through which a drawstring 24 is run. Padding 26, having generally the same shape as the layer of fabric 16, is provided. The padding 26 serves as a layer of heat resistant material juxtaposed to the lower surface of the fabric 16. Padding 26 is preferably a layer of foam polymeric material such as foam polyurethane and is approximately 1/4 inch thick. The layer of padding 26 is substantially thicker than the layer of fabric 16. However, the edges of the padding 26 are coextensive with and uniformly spaced from the edges 20 of the ironing surface 12 to form the cover 14 on which the ironing is effected. The padding 26 may or may not be adhesively bound to the layer of fabric 16.
When installed on an ironing board, the padding 26 as shown in FIG. 2 is coextensive with the edges 20 of the ironing surface 12. A marginal skirt 28 can be turned down and under the ironing surface 12. As seen in FIG. 3, when drawstring 24 is tightened, welting 22 is snugly held on the undersurface of the ironing surface 12.
The present invention is further described by reference to the following specific, non-limiting example.
EXAMPLE
A natural loom-state greige cotton fabric was coated with an aqueous solution of "ETERNA COPPER #120" powder produced by Atlantic Powdered Metals, Inc. of New York, N.Y. and "METALLIC BINDER 113" of Polymer Industries of Greenville, S.C. The properties of the "ETERNA COPPER #120" powder utilized were as follows:
Purity: 99% copper with trace amounts of zinc and/or tin
Particle size: 33 to 44 microns
Heat stability: 300° C. to 320° C.
Screen analysis: 98% through 200 mesh
Specific gravity: 88
The properties of the binder utilized were as follows:
Appearance: white viscous emulsion
pH: 6.0±0.5
Viscosity: 6 to 8,000 cps
Boiling point: Approximately 212° F.
Specific gravity: 1.04
The copper powder was coated with silicate prior to introduction into the solution to impede discoloration.
The formulation employed for the coating was as follows:
"METALLIC BINDER 113" (X354-13) binder--95 lbs
"ETERNA COPPER #120" powder--12 lbs
"SPECTRACHEM THICKENER NO. W6948B"--3 pints
Water--105 lbs
Water and thickner were first homogenized together. The binder was then added and the resultant mixture was then homogenized. The copper powder was then introduced into the mixture and once again the resultant mixture was homogenized.
The coating was applied to the fabric by use of a rotary screen printer. After coating, the web was dried in a multi-pass dryer at approximately 325° F. to 350° F.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. | 4y
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The present invention relates to compositions inhibiting the development of a pathological addiction to alcohol.
FIELD OF THE INVENTION
The present invention is useful in the food industry as an additive to alcoholic and alcohol-free beverages, as an agent for prevention of alcoholism and can be employed for increasing biological value of foodstuffs (confectionery, baked goods).
BACKGROUND OF THE INVENTION
Known in the art are pharmacological agents widely employed at the present time for the treatment of patients suffering from chronic alcoholism and intended for improvement of the general resistence of the organism (tonics, vitamin therapy) and formation of negative conditional reflexes in patients for alcohol. Furthermore, also widespread have become the agents reducing toxic post-effects of alcohol and its metabolites (desintoxication therapy), as well as preparation arresting abstinence syndrom. However, the above-mentioned complex of antialcoholic therapy is aimed predominantly at the treatment of clinically pronounced forms of alcoholism or bears the character of an antire currence therapy.
The known complex of pharmacological preparations is not intended for a broad circle of consumers of alcoholic beverages which excludes the possibility of using these preparations for a primary prophylaxis of alcoholic abuse and chronical alcoholism.
Known in the art are synthetic preparations hindering pathological influence of alcohol on a human organism upon its intake by way of lowering the level of ethanol concentration in blood. These preparations contain, as an active ingredient, at least one compound from the group of carbohydrates and polyhydric alcohols and/or at least one compound from the group of compounds consisting of a cyclic tricarboxylic acid or containing its residue, and/or at least one compound protecting the stomach and acting as a "lining" thereon, and/or at least one compound from the group of choleretics. These preparations serve as liver-protecting agents and detoxicants upon intake of ethanol; they also cure pathological phenomena caused by resorption of alcohol (cf. French Pat. No. 2,340,725).
The above-mentioned effect is attained by normalization of the ratio of oxidized forms of pyridinenucleotides to reduced nucleotides, thus ensuring realization of carbohydrate metabolism through the cycle of tricarboxylic acids. Another active principle of these compositions are compounds lowering resorption of ethanol in the gastrointestinal tract so as to achieve a synergistic effect--reduction of the level of ethanol in blood. It is obvious that in this case the effect from intake of ethanol expected by the consumer (euphoria, relaxation) is substantially lowered. Furthermore, the prior art preparations are recommended as pharmaceutical forms to be administered either prior to ethanol intake, or simultaneously therewith, or is advisable after consumption of alcohol. These compositions, however, do not comprise food additives including those incorporated in alcoholic beverages, since they noticeably change the organoleptic value of the product.
It is an object of the present invention to provide such a composition which would actively influence the negative effects of ethanol and its toxic products of oxidation in the organism by normalization of the main metabolic routes of degradation of ethanol and its metabolites.
It is another object of the present invention to provide such a composition which would be useful as an all-purpose food additive to alcoholic or alcohol-free beverages without impairing their organoleptic characteristics.
SUMMARY OF THE INVENTION
These objects are accomplished by the provision of a composition inhibiting the development of a pathological addiction to alcohol which, according to the present invention, comprises the following ingredients, mg/g:
______________________________________leukoanthocyanes 219-270catechins 153-187flavonols 81-99lignin 68-83reducing sugars 216-264pectin 18-22free aminoacids 27-33organic acids 36-44sterols 4.5-5.5methylsterols 1.35-1.65dimethylsterols 1.98-2.42lignans 13.5-16.5lignan glycosides 9-11phenolic acids 13.5-16.5phenol aldehydes 4.5-5.5alkylferulates 4.5-5.5.______________________________________
The composition according to the present invention comprises a combination of compounds occurring in nature. The composition has a pronounced capability of effecting processes of ethanol metabolism without switching to unfavourable routes of the organism's utilization of ethanol; as a result, the process of formation of a physical dependence on alcohol is delayed, the level of its consumption is lowered and certain alcoholic behaviour excesses disappear. Furthermore, the composition according to the present invention is not toxic and safe after many-year consumption; it has positive organoleptic characteristics and can be useful as a food additive to alcoholic and alcohol-free beverages.
Other objects and advantages of the present invention will now become more fully apparent from the following detailed description of a composition inhibiting the development of a pathological addiction to alcohol with reference to examples illustrating its particular embodiments.
DETAILED DESCRIPTION OF THE INVENTION
The composition according to the present invention contains, as leukoanthocyanes, leukodolphinidine, leukocyanidine and leukopelargonidine. As catechins it contains (-)epigallocatechin, (±)gallocatechin, (-)epicatechin, (+)catechin and (-)epicatechingallate. As flavanols the composition according to the present invention contains kaempferol-3-monoglucoside, quercetin-3-monoglucoside, myricetin-3-monoglucoside and astragalin. A reducing sugars it contains D-glucose, D-fructose, saccharose, rafinose, arabinose, xylose. As free amonoacids the composition according to the present invention contains lysine, histidine, arginine, aspartic acid, threonine, serine, glutamic acid, proline, glycine, alanine, cystine, valine, methionine, isoleucine, leucine, tyrosine and phenylalanine. As organic acids it contains tartaric acid, malic acid, citric acid, ascorbic acid, α-ketoglutaric acid, fumaric acid, galacturonic acid, glyceric acid, glycolic acid, glycouronic acid, oxalic acid, succinic acid, shikimic acid. As sterols the composition according to the present invention contains β-cetosterol, stigmasterol, kaempesterol. As methylsterols it contains obtusifoliol, citrostadienol. As dimethylsterols it incorporates α-amyrin, β-amyrin, lupeol, taraksterol, taraxasterol, germanicol. As lignans the composition according to the present invention contains oxymatairesinol, matairesinol, pinoresinol, liovyl, isolariciresinol and olivil. As lignan glycosides it contains querinol arabinoside and querinol xyloside. As phenolic acids it contains paraoxybenzoic acid, protocatechinic acid, gallic acid, vanillic acid and syringic phenolic acids. As phenolic aldehydes the composition according to the present invention contains vanilline, syringic aldehyde, sinapic aldehyde and coniferyl aldehyde. As alkylferulates it contains alkyl esters of ferulic acid with the alcohol moiety being represented by octadecanol, eicosanol, docosanol, tetracosanol, hexacosanol.
The above-mentioned composition of the hereinbefore-listed ingredients can be also obtained in the form of naturally-occurring complexes of biologically active substances of the vegetable origin.
The above-mentioned composition of the hereinbefore-listed ingredients is soluble in water, ethanol and aqueous alcoholic solutions.
The composition according to the present invention has a low toxicity: LD 50 is 36.5 ml per 1,000 g of bodymass of a rat.
We have carried out pharmacological studies of the effect of the composition according to the present invention on processes of ethanol consumption and on the formation of a physical dependence of animals and human beings.
Under conditions of a chronical experiment (15 weeks) on mature male rats of Wistar line the level of ethanol consumption was studied under the conditions of free choice between water and 15% ethanol. Prior thereto the rats were tested for resistance to ethanol by the "side posture" procedure upon an intraperitoneal administration of a 25% ethanol at the rate of 4.5 g/kg of the bodymass of the animals. In the experiment rats with similar characteristics of a high tolerance towards ethanol were used. Later on the animals were placed into cages with calibrated drinking bowls under conditions of free choice between 15% ethanol and water, and the daily consumption of the liquids was recorded.
The control group was composed of animals (12 rats) that consumed 15% ethanol.
In the test group (12 rats) the composition according to the present invention was added to 15% ethanol in the drinking bowl in the amount of 1 ml per 50 ml of 15% ethanol. After 13 weeks of active alcoholization the animals were deprived of the access to alcohol for 10 days (deprivation period) and then the amount of consumed solutions was recorded again. The experimental data are shown in Table 1.
In the group of control animals the deprivation period proceeded with abstinence phenomena which were manifested by a changed behaviour of the animals, the signs of tremor were recorded, a moderate dishevelling of hair was noted. At the same time, in the control group no signals of abstinence were observed.
The character of consumption of 15% ethanol under free choice conditions in the control group was different from that of consumption of 15% ethanol with the composition according to the present invention in the test group. Beginning from the 8-th week a clearly pronounced trend towards reduction of ethanol consumption in combination with the composition according to the present invention was observed and after deprivation this difference was exceeding 100%. An important indicator of a formed physical dependence on ethanol in the control group was an increased rate of ethanol consumption after a 10-days' deprivation by 12%. In the test group the consumption of ethanol in combination with the composition according to the present invention after deprivation remained at the same level.
Addition, to 15% ethanol, of the composition according to the present invention under conditions of a long-time forced alcoholization (38 months) with the absence of water in the food diet has resulted in a substantial redistribution of animals in groups of alochol consumption (Table 2).
The conditions of this experiment contemplated an individual control of consumption of test solutions in groups of animals; among the rats administered with alcohol incorporating the composition according to the present invention the number of heavily-drinking animals was certainly smaller.
TABLE 1__________________________________________________________________________Effect of the composition according to the present invention on theamount of consumed 15%ethanol on a daily basis (in ml/kg of 1 animal's bodyweight) under freechoice conditions Statistical Time of consumption (in weeks) parameter 1 2 3 4 5 6 7 8 9 10 11 12 13 151 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17__________________________________________________________________________ Amount of M ± m 28.9 20.1 22.5 26.6 28.3 25.6 27.5 26.8 24.0 28.2 29.7 29.4 24.7 Depri- 29.4 consumed 15% 1.86 1.18 2.29 2.05 1.86 1.97 2.32 1.33 2.06 2.25 1.76 3.44 1.29 vation 3.12 ethanol 10 days (control group) Amount of M ± m 33.8 32.2 37.0 34.0 25.9 26.6 29.8 15.3 18.9 22.0 22.0 20.0 13.0 13.0 consumed 15% 3.88 4.09 2.93 3.11 2.53 2.26 1.3 1.49 1.36 2.17 1.66 2.42 2.12 2.41 ethanol with p 0.05 0.05 0.01 0.2 0.1 -- -- 0.01 0.001 0.001 0.2 0.1 0.05 0.00 addition of the composition of this invention (1 ml per 50 ml of ethanol)__________________________________________________________________________
TABLE 2______________________________________Effect of the composition according to the presentinvention on distribution of rats according to therate of consumption of a 15% ethanol (in percent)(forced alcoholization)Groups of Alcoholization time*animals 3 months 6 months 8 months______________________________________Low-drinking (20- 26/45 73/76 67/7960 ml per 1,000 gof the bodymass)Medium-drinking 31/12 22/21 21/15(60-80 ml per1,000 g of thebodymass)Heavily-drinking 43/13 5/3 12/6(above 80 ml per1,000 g of thebodymass)______________________________________ *NOTE: in the numerator consumption of a 15% ethanol, in the denominator consumption of a 15% ethanol with the addition of a composition according to the present invention.
To avoid possible organoleptic effect of the composition according to the present invention on the level of ethanol consumption under free-choice conditions parallel experiments have been carried out where the composition was introduced intragastrically, not into the test solution. The test results turned to be identical irrespective of the routes of administration of the composition according to the present invention.
The gas-liquid chromatography method was used to determine the amount of ethanol in blood of animals of the test and control groups that were given the test solution for the period of 3 months. 90 minutes prior to slaughtering the animals they were intraperitoneally administered with a 25% ethanol (control group) and a 25% ethanol in combination with the composition according to the present invention in the ratio of 1:50 (test group).
The test results (Table 3) point to an essential increase (by more than 4 times) of ethanol in the blood of animals that were previously administered for a long time with the composition according to the present invention.
The rate of elimination of ethanol from blood depend, first of all, on activity of alcoholdehydrogenase (ADG) which has been studied against the background of an acute and chronic alcoholic intoxication. Upon a single-time intraperitoneal administration, to animals, of a 15% ethanol in the dose of 4.5 g/kg of the bodymass, 30 minutes thereafter the activity of alcoholdehydrogenase is 8.51 mM/min/l relative to the intact group; the composition additive according to the present invention inhibits activity of enzymes in the presence of ethanol which is 5.86 mM/min/l.
TABLE 3______________________________________Effect of the composition according to the presentinvention on elimination of ethanol after the additionof a 25% ethanol 4.5 g/kg of the animals' bodyweight Content of Statistical ethanol inExperiment parameter blood, %______________________________________1. Digested content M ± m 0.72 ± 0.14 (introduction of a 25% ethanol) 72. 3-months' consump- M ± m 1.0 ± 0.14 tion of a 15% p 0.2 ethanol (intro- duction of 25% ethanol) 143. 3-months' consump- M ± m 2.52 ± 0.57 tion of a 15% p 0.01 ethanol in com- bination with the composition of the present invention (admini- stration of 25% ethanol) 114. 3-months' consump- M ± m 4.26 ± 0.78 tion of a 15% p 0.001 ethanol in com- bination with the composition of this invention (administration of 25% ethanol + composition), 1:50 11______________________________________
In chronical experiments upon introduction of ethanol (passive alcoholization) over the period of 1.5 months of a daily administration of 15% ethanol and ethanol in combination with the composition according to the present invention in the test dose of 1 g/kg the data have been obtained which prove the results of the previous experiment (see Table 4).
Under conditions of free choice between 15% ethanol and water (control group) and between a 15% ethanol with the composition according to the present invention and water after 1.5 and 3 months of consumption the activity of alcoholdehydrogenase was studied prior to and after deprivation. The results thus obtained are shown in Table 5.
Therefore, the composition additive according to the present invention decelerates oxidation of ethanol in the liver by inhibiting activity of alcoholdehydrogenase.
Observations were carried out to study the lipoid and carbohydrate metabolism in animals upon administration of the composition according to the present invention against the background of a 3- and 6-months' alcoholization.
TABLE 4__________________________________________________________________________Activity of alcoholdehydrogenase in blood serum and liverupon administration of a 15% ethanol in combinationwith the composition according to the present invention orally for 1.5months Activity of alcohol- Activity of alcohol- dehydrogenase dehydrogenase according in blood serum by to Bonischoen method Ethanol in the Skursky method serum liver blood mM/min/l mM/min/l mM/min/l μM/ml__________________________________________________________________________ 15% ethanol 3.1 ± 1.17 3.15 ± 0.14 47.02 ± 1.91 16.21 ± 1.4 15% ethanol + 2.63 ± 0.49 2.86 ± 0.05 37.4 ± 1.61 21.87 ± 2.5 composition of this invention Composition of 2.76 ± 0.33 2.21 ± 0.05 34.39 ± 2.6 4.32 ± 0.4 this invention (aqueous solu- tion 1:50) Physiological 2.51 ± 0.29 2.51 ± 0.06 40.5 ± 3.29 4.9 ± 0.6 solution Intact 2.6 ± 0.33 2.46 ± 0.09 40.51 ± 1.3 4.14 ± 0.3__________________________________________________________________________
TABLE 5______________________________________Activity of alcoholdehydrogenase at a freechoice of the test solutions Activity of alcohol- dehydrogenase, mM/min/l 1.5 months 3 months of consumption of consumption prior to after prior to after depriva- depriva- depriva- depriva- tion tion tion tion______________________________________1. 15% ethanol 2.7 ± 3.61 ± 2.64 ± 4.3 ± 0.26 0.48 0.27 0.632. 15% ethanol + 1.87 ± 3.35 ± 3.95 ± 2.63 ± composition of 0.22 0.44 0.66 0.49 this invention3. Intact 4.33 ± 4.79 ± 2.2 ± 3.08 ± 1.08 0.64 0.28 0.58______________________________________
To this end, over the period of 3 and 6 months the rats were intragastrically administered with 2 ml of the hereinbelow-specified solutions per 100 g of the bodymass. In the control: Group 1--distilled water; Group II--15% ethanol; Group III--15% ethanol containing a 5% composition according to the present invention; Group IV--aqueous solution of the composition according to the prevent invention.
The results thus obtained are shown in Tables 6, 7, 8 and 9 hereinabelow.
Then we have carried out pharmacological tests of the composition according to the present invention as an agent for improving general resistance of the organism. For this purpose the effect of the composition according to the present invention on the heat-resistance of rats has been studied.
(I) Overheating of nondescript female rats (60 animals) is effected by irradiation with an UHF-field by means of an instrument for a microwave therapy with the frequency of 2,375 mHz-17 mA for 10 days once a day over the period of 4 days. The test composition is administered in the dose of 2.5 ml/kg (intragastrically in all series of experiments) for 5 days before the beginning of irradiation and, on the day of experiment, one hour before irradiation. The death rate of rats is assessed after a 4-times' irradiation.
It has been found that during one day after the last irradiation in the control group 22% of the animals died, whereas among the rats administered with the composition according to the present invention the death rate was 11% (p<0.01).
(2) Overheating of male rats of the Wistar line is effected in a thermostatted cabinet at the temperature of 43° C. The test composition in the dose of 2.5 ml/kg is administered for the preventive purposes over the period of 20 days. The rectal temperature and death rate of the animals are assessed.
It has been found that in the control group 76% of the animals (28 animals out of 37) died, while against the background of the composition according to the present invention 56% of the rats died (22 rats out of 39; p<0.001). The composition provided no effect on the rectal temperature.
(3) Under the same conditions of overheating of male rats of the Wistar line the composition according to the present invention is administered prophylactically over 48 days in the dose of 1 ml/kg.
It has been found that in the control group 54% of rats (30 animals out of 55) died, while upon overheating against the background of a long-time administration of the composition according to the present invention the death rate was 42% (24 rats out of 57; p<0.001).
TABLE 6__________________________________________________________________________Variation of the content of neutral lipoids in the liver of rats fed withthe solutionsfor 3 months (in % of the total lipoids, M ± m) Groups of animals III IV aqueous solution 15% ethanol + of the compo- composition I II sition of this of this V control distillate invention invention 15% ethanol__________________________________________________________________________Cholesterol esters 14,5 ± 1.10 14.5 ± 0.49 .sup. 12.5 ± 0.93.sup.1 .sup. 12.5 ± 0.48.sup.1 15.0 ± 1.21% of variation 100 86 86 103Triglycerides 13.6 ± 0.55 .sup. 17.2 ± 1.11.sup.2 .sup. 20.1 + 0.84.sup.3 .sup. 20.6 + 1.77.sup.3 .sup. 20.1 + 1.04.sup.3% of variation 127 148 151 148Free fat acids 12.8 ± 1.60 12.8 ± 0.48 12.3 ± 0.50 11.5 ± 0.53 .sup. 10.6 ± 0.92.sup.1% of variation 100 96 90 83Cholesterol 16.6 ± 0.9 17.2 ± 0.63 16.1 ± 0.91 .sup. 14.2 ± 0.67.sup.1 15.3 ± 1.22% of variation 104 97 86 92Residual fraction 32.5 ± 1.05 38.3 ± 0.97 39.0 ± 1.02 41.2 ± 1.30 39.0 ± 1.00__________________________________________________________________________ .sup.1 p < 0.05; .sup.2 P < 0.02; .sup.3 P < 0.01 p -- probability
TABLE 7__________________________________________________________________________Variation of the content of neutral lipoids in the liver of rats fed withthesolutions for 6 months (in % of the total lipoids, M ± m) Groups of animals III IV 15% ethanol + aqueous solu- composition tion of the I II of this compositionNeutral lipoids Control distillate 15% ethanol invention of the invention__________________________________________________________________________Cholesterol esters 16.9 ± 0.69 16.52 ± 0.70 16.62 ± 0.35 16.74 ± 0.27 15.81 ± 0.14% of variation 99 100 100 95Triglycerides 15.16 ± 0.21 13.88 ± 0.12 .sup. 18.19 ± 0.26.sup.1 .sup. 14.18 ± 0.22.sup.1 .sup. 13.64 ± 0.42.sup.1% of variation 92 120 94 90Free fatty acids 16.67 ± 0.48 17.21 ± 0.11 .sup. 14.0 ± 0.39.sup.1 17.30 ± 0.37 18.66 ± 0.88% of variation 103 84 104 112Cholesterol 17.28 ± 0.26 17.07 ± 0.16 16.61 ± 0.69 16.72 ± 0.89 17.06 ± 0.19% of variation 99 96 97 99Residual fraction 33.93 ± 0.40 35.38 ± 0.74 34.58 ± 0.47 35.06 ± 0.52 34.83 ± 0.61__________________________________________________________________________ .sup.1 p < 0.05; .sup.2 p < 0.02
TABLE 8__________________________________________________________________________Variation of activity of lysosomal hydrolases in the liver of rats uponconsumption of ethanol and the composition of this invention for 3monthsand 6 months (nanomol/ml/min, M ± m) 3 months 6 monthsGroups of animals β-glycosidase β-galactosidase β-glucosidase β-galactosidase__________________________________________________________________________ Control 0.47 ± 0.04 0.33 ± 0.01 0.49 ± 0.05 0.35 ± 0.011. Distillate 0.43 ± 0.01 0.35 ± 0.01 0.54 ± 0.08 0.43 ± 0.02 % of variation 91 106 110 78 of the controlII. 15% ethanol 0.58 ± 0.08.sup.1 0.37 ± 0.04 .sup. 0.87 ± 0.09.sup.2 .sup. 0.86 ± 0.06.sup.3 % of variation 123 112 178 247 of the controlIII. 15% ethanol + 0.50 ± 0.05 0.35 ± 0.06 .sup. 0.66 ± 0.08.sup.1 0.26 ± 0.01 composition of this invention % of variation of 106 106 135 75 the controlIV. Aqueous solution of 0.40 ± 0.02 0.31 ± 0.03 0.38 ± 0.05 .sup. 0.25 ± 0.01.sup.1 composition of this invention % of variation of the 85 94 78 70 control__________________________________________________________________________ .sup.1 p < 0.05; .sup.2 p < 0.01; .sup.3 p < 0.001
TABLE 9__________________________________________________________________________Variation of the content of carbohydrate-containing biopolymers in theliver ofrats fed with ethanol and with the composition of the invention for 3monthsand 6 months (mg %, M ± m)Groups of 3 months 6 monthsanimals Hexoses Hexosamines Hexoses Hexosamines__________________________________________________________________________ Control 26.68 ± 1.54.sup. 32.53 ± 2.37 26.26 + 1.43 49.00 ± 1.76 Distillate 18.67 ± 1.12.sup.1 29.60 ± 2.52 20.45 ± 1.72 .sup. 68.53 ± 6.97.sup.2 % of variation 70 91 78 140 of the control Aqueous solution 33.35 ± 2.73.sup.1 36.02 ± 1.47 28.91 ± 1.34 102.43 ± 7.63.sup.3 of the composition of this invention % of variation of 125 111 110 209 the control 15% ethanol + com- 18.43 ± 1.27.sup.1 28.10 ± 2.65 .sup. 19.71 ± 1.10.sup.1 .sup. 84.72 + 4.21.sup.3 position of this invention % of variation 69 86 75 173 of the control 15% ethanol 16.67 ± 1.22.sup.1 .sup. 25.84 ± 1.77.sup.1 .sup. 16.32 ± 1.00.sup.2 .sup. 30.22 ± 5.41.sup.2 % of variation 62 79 62 62 of the control__________________________________________________________________________ .sup.1 p < 0.05; .sup.2 p < 0.01; .sup.3 p < 0.001
(4) Overheating of male rats of the Wistar line was effected in much the same manner. The test composition was administered in the dose of 1 ml/kg 50 minutes prior to overheating. The overheating duration is 40 minutes and 2 hours. The animals were killed by decapitation. Tested were: the content of glycogen (herein and in other cases--by the Zeifter method); activity of hexokinase and glucose-6-phosphatedehydrogenase (herein and in other cases--by the formation of nicotinamidedinucleotidephosphoric acid (NADPxH).
It has been found that in overheating of the rats for 40 minutes the composition inhibited the drop of the content of glycogen, as well as of the activity of hexokinase and glucoso-6-phosphatedehydrogenase in the liver (see Table 10 hereinbelow).
Upon overheating for 2 hours the test composition provided no effect on the level of the studied parameters.
Overcooling of male rats of the Wistar line was caused by placing the animals into a refrigerator chamber at a temperature of 5° C. for 1 and 2 hours. The composition according to the present invention was administered in the dose of 1 ml/kg 60 minutes before cooling.
It has been found that upon overcooling of rats during the first hour there is observed as decrease of glycogen stock in the liver, as well as lowering of activity of hexokinase and glucoso-6-phosphatedehydrogenase in this organ. A preliminary administration of the composition according to the present invention to the animals inhibited lowering of the studied parameters (see Table 11). Upon a 2-hours' cooling the composition according to the present invention provided no protective effect.
The effect of the composition according to the present invention on animals' resistance to a muscular fatigue has been also studied. To this end:
(1) Experiments are carried out on non-descript male mice with a mass of 28-33 g. The test composition is administered enterally by means of a probe to three groups of animals in three doses: 0.1, 0.15, 0.22 ml/20 g one hour prior to the muscular work. The control animals are carried out on an "endless rope" apparatus. The duration of mice run along a vertical downwardly moving rope till a complete exhaustion was assessed. The dose of the composition extending the duration of mice run by 33% was found by graphical plotting. Activity of the studied composition was expressed in conditional units--stimulant effect units (SEU 33 ).
As a result of tests it has been found that the muscular workability of mice was increasing proportional to the dose of the extract.
TABLE 10______________________________________Effect of the composition according to the presentinvention on variation of glycogen (mg %), hexokinase(μmol of NADPxH/min/g of the tissue), glucoso-6-phos-phatedehydrogenase (μmol NADPxH/min/g of the tissue)upon overheating (45° C.) Glucoso-6- phosphatede-Group of animals Glycogen Hexokinase hydrogenase______________________________________40 minutes of overheating1. Normal 3,226 + 148 0.42 + 0.025 1.80 + 0.612. Overheating 387 + 209 0.34 + 0.19 1.57 + 0.095 p < 0.005 p < 0.020 p < 0.0503. Overheating + 2,968 + 121 0.40 + 0.18 1.71 + 0.077 composition p < 0.030 p < 0.030 p < 0.30 of the present invention2 hours of overheating1. Normal 4,628 + 207 0.50 + 0.019 1.56 + 0.0582. Overheating 2,175 + 271 0.31 + 0.027 1.17 + 0.095 p < 0.0001 p < 0.0001 p < 0.0033. Overheating + 2,869 + 219 0.29 + 0.020 1.04 + 0.081 composition p < 0.060 according to the present invention______________________________________ p in comparison of Groups 1-2 and Groups 2-3
upon administration of the composition according to the present invention in the maximum dose (0.22 ml/kg) the workability increased by 41% as compared to the control (see Table 12 hereinbelow).
(2) As a model of an experimental influence swimming of rats was used (herein and in other cases--male rats of the Wistar line) at the temperature of water of 30° C. The composition according to the present invention was administered to mice in the dose of 10 ml/kg one hour prior to the swimming. The ultimate duration of swimming was assessed (i.e. swimming till exhaustion).
It has been found that the rats' swimming duration in the control was 392.6±29.0 minutes, whereas against the background of the composition according to the present invention it was 519.4±40.0 minutes, i.e. by 32% longer (p=0.023).
(3) The composition according to the present invention was administered one hour before the swimming in the dose of 1 ml/kg, whereafter the animals were allowed to swim for 15 minutes or 2 hours. The state of the animals was judged by the content of glycogen, activity of hexokinase and glucoso-6-phosphatedehydrogenase in the liver.
It has been shown that the swimming of rats for both time limits specified hereinabove caused a decrease of glycogen content in the liver and lowering of the activity of hexokinase and glucoso-6-phosphatedehydrogenase. A preliminary administration of the composition according to the present invention inhibited the decrease of the studied parameters after a 2-hours' swimming, but did not affect their level after a 15-minutes' muscular load (see Table 13).
(4) The composition according to the present invention was administered one hour before a 15-minutes' swimming. The content of cyclic adepasinemonophosphate in adrenal glands, the content of cyclic guanosinemonophosphate in adrenal glands and in the liver was determined by the radioimmune method by means of sets Ammerscham. A number of rats from the test and control groups were allowed to rest after swimming for one hour, whereafter the same characteristics were studied in them too.
The swimming of rats caused elevation of the level of cyclic adepasinemonophosphate and cyclic guanosinemonophosphate in adrenal glands, as well as reduction of the content of cyclic guanosinemonophosphate in the liver (acute stress at an energy supply at the account of glycolysis). After the animals' rest for one hour the level of cyclic adepasinemonophosphate and that of cyclic guanosinemonophosphate were turned to normal values. The composition according to the present invention provided no effect on the content of cyclic adepasinemonophosphate and cyclic guanosinemonophosphate in adrenal glands, but the biosynthesis of cyclic guanosinemonophosphate in the liver one hour after swimming came to its normal values (see Table 14 hereinbelow).
The composition according to the present invention was also studied for resistance of rats to hypokinesia which was induced by keeping animals in individual cell-cages for 2 days. The test composition was administered during the entire period of hypokinesia in the dose of 1 ml/kg twice a day.
As a result of hypokinesia a reduction of glycogen stock in the liver was observed along with a decrease of concentration of cholesterol in adrenal glands and lowering of the activity of alcoholdehydrogenase (as determined by the method suggested by Schleisinger et al., 1966). In the animals administered with the composition according to the present invention the reduction of the studied parameters after hypokinesia was less pronounced (see Table 15 hereinbelow).
We have also studied the effect produced by the composition according to the present invention on resistance of animals to different chemical factors.
(1) As a model of an injuring effect a hexenal narcosis was used. The composition according to the present invention was administered to rats in the doses of 2.5, 5.0, 10.0 ml/kg; 2 hours thereafter hexenal was administered intraperitoneally in the dose of 19.8 mg/100 g. The duration of the side posture state of the animals was assessed.
It has been found that the duration of the hexenal narcosis of the control rats was 90.6±3.9 minutes, while against the background of the composition according to the present invention administered in the dose of 2.5 mg/kg it was 85.5±5.4 min, in the dose of 5.0 ml/kg-75.7±3.1 min (83.6%, p=0.009), in the dose of 10.0 ml/kg-72.9±3.7 (80.5%, p=0.005) that is, the composition according to the present invention exerted an awakening dose-depending effect.
(2) In experiments on mice narcosis was caused by means of sodium thiopental in three doses: 62.5, 75.0 and 100 mg/kg intraperitoneally. The composition according to the present invention was introduced in the dose of 10.0 ml/kg two hours before the injection of thiopental. The speed of occurrence of the side posture was determined, as well as the duration of the side posture period and the death rate of the animals was assessed.
It has been found that out of the mice administered with thiopental (62.5 mg/kg) against the background of the composition according to the present invention the side posture was acquired by 22% of the animals, whereas in the control (thiopental)--100% of the mice (p=0.001). The duration of the side posture period in the control was 53.5 minutes, in the experiment--120 minutes (p<0.05).
In the group of mice administered with thiopental in the dose of 75 mg/kg 28% of the animals died, whereas in the group of rats administered with thiopental against the background of the composition according to the present invention 12.5% of the animals died (p<0.001). In the control group the side posture period lasted for 30.0±0.0 minutes, whereas against the background of the composition according to the present invention--260±0.0 minutes (p<0.05). The death rate of the animals in both groups was the same.
The composition according to the present invention has been also studied for certain aspects of carbohydrate metabolism. To this end:
(1) In experiments on intact animals under conditions of a conventional feeding diet the composition according to the present invention was administered twice a day over 5 days. In this and subsequent series of experiments the concentration of glucose in blood was determined by the anthrone method, the content of glycogen in the liver--by the Zeifter method.
It has been found that a 5-days' administration of the composition according to the present invention to intact animals caused a certain increase of sugar concentrations in blood and of glycogen in the liver (see Table 16).
(2) The study of carbohydrate metabolism has been performed on rats subjected to starvation for 18 or 48 hours. The test composition was administered in the dose of 1 mg/kg 1 hour prior to slaughter of the animals. The content of sugar in blood, the level of insulin in blood serum were determined by the radioimmune method.
It has been shown that a 18-hours' starvation of rats has caused reduction of the glycemia level. The test composition inhibited reduction of the sugar content in blood (see Table 16). The rats' starvation for 48 hours has caused a certain reduction of the sugar content on blood and glycogen content in the liver. This was accompanied by a lowered concentration of insulin in blood serum.
In a preliminary 5-days' administration of the composition according to the present invention to the animals only a trend was observed towards preservation of a previous level of sugar in blood and of glycogen in the liver. In this case the content of insulin in blood was certainly higher than in the control (subjected to starvation) animals (see Table 16 hereinbelow).
(3) The effect of the composition according to the present invention on the carbohydrate metabolism was studied on rats fed with an excessive diet. The composition was administered in the dose of 1 ml/kg 1 hour before slaughter.
Under conditions of an excessive diet of the rats the studied extract provided no effect on the concentration of sugar in blood, but it certainly increased the content of glycogen in the liver and reduced the level of insulin in blood (see Table 16 hereinbelow).
We have studied antioxidation properties of the composition according to the present invention. To this end, in order to activate a peroxy oxidation of lipoids, in rats of the Wistar line (40 animals) stress was caused by suspending them by the neck skin fold for 24 hours. The test group of animals was administered once with the composition of the present invention in the dose of 1 ml/kg prior to suspending. The accumulation of lipoid peroxides in the liver was assessed by the concentration of malonic dialdehyde in this organ.
It has been found that the composition according to the present invention caused no changes in the content of malonic dialdehyde in the liver of intact rats. In the rats underwent the stress treatment the content of malonic dialdehyde in the liver increased by 6 times, whereas in the case of stress against the background of the composition according to the present invention the rate of accumulation of malonic dialdehyde was noticeably smaller (normal--86.5±29.0; stress--452±20; stress+composition according to the present invention--296±15; p=0.001).
Consequently, the composition according to the present invention possesses antioxidant properties.
We have also studied biochemical characteristics of human beings administered with the composition according to the present invention against the background of alcoholization.
Under clinical conditions the effect of the composition according to the present invention on the rate of elimination of ethanol from blood and on activity of blood alcoholdehydrogenase, as well as on activity characteristics of lysosomal hydrolases, the level of protein-combined hexosoamines and on fractions of neutral lipoids was studied. The first group of patients who took part in the studies consisted of persons suffering from chronic alcoholism and subjected to a stationary treatment; the second group was composed of persons belonging to the Mongoloid race genetically intolerant to alcohol; the third group--substantially healthy Europoids who did not abuse alcohol.
TABLE 11______________________________________Effect of the composition of this invention on variation ofthe content of glycogen (mg %) and activity of hexokinase(μmol NADPxH/min/g of the tissue) and glucoso-6-phosphate-dehydrogenase (μmol/NADPxH/min/g of the tissue) in the liverof rats upon overcooling (5° C.) Glucoso-6- phosphate-Group of animals Glycogen Hexokinase dehydrogenase______________________________________1 hour of overcooling1 Normal 4109 + 195 0.51 + 0.017 1.62 + 0.0782 Overcooling 2794 + 207 0.41 + 0.022 1.20 + 0.101 p < 0.0001 p < 0.003 p > 0.0043 Overcooling + p < 0.020 p < 0.020 composition of this invention2 hours of overcooling1 Normal 3078 + 189 0.63 + 0.017 1.57 + 0.0752 Overcooling 1754 + 237 0.47 + 0.028 1.27 + 0.103 p < 0.001 p < 0.0001 p < 0.0373 Overcooling + 1908 + 226 0.44 + 0.022 1.41 + 0.091 composition of this invention______________________________________ p in comparison of Groups 1-2 and 2-3.
TABLE 12______________________________________Stimulant effect of the composition of this inventionon duration of the muscular workability of mice in an"endless rope" apparatus Duration of the run of the miceGroup of animals minutes % p______________________________________Physiological 27.0 ± 2.1 100solution (13)Composition of theinvention 0.1 ml/20 g (10) 30.0 + 1.8 111 0.50.15 ml/20 g (11) 32.0 + 2.8 118 0.50.22 ml/20 g (15) 38.0 + 2.7 141 0.001______________________________________ Note: Shown in brackets is the number of animals.
TABLE 13______________________________________Effect of the composition of this invention on thecontent of glycogen (mg %) and activity of hexokinase(μmol NADPxH/min/g of the tissue) and glucoso-6-phos-phatedehydrogenase (μumol NADPxH/min/g of the tis-sue) in the liver of rats in swimming (water tem-perature 30-32° C.) Glucoso-6-Group of phosphatede-animals Glycogen Hexokinase hydrogenase1 2 3 4______________________________________Swimming for 15 minutes1 Normal 4216 + 216 0.50 + 0.019 1.44 + 0.0682 Swimming 2993 + 278 0.31 + 0.029 1.01 + 0.094 p < 0.002 p < 0.001 p < 0.0103 Swimming + 2902 + 202 0.35 + 0.015 0.98 + 0.101 composition of the inventionSwimming for 60 minutes1 Normal 3511 + 201 0.54 + 0.025 1.51 + 0.0752 Swimming 2633 + 163 0.37 + 0.024 1.13 + 0.095 p < 0.004 p < 0.0001 p < 0.0083 Swimming + 3089 + 133 0.44 + 0.021 1.39 + 0.071 composition of p < 0.040 p < 0.040 p < 0.040 this invention______________________________________ p in comparison of Groups 1-2 and 2-3
TABLE 14______________________________________Effect of the composition of this invention on thecontent of CAMP in adrenal glands, CGMP in adrenalglands and liver of rats after a muscular load and restGroup of CAMP, pmol CGMP, pmolanimals adrenal glands adrenal glands liver1 2 3 4______________________________________1 Intact 8.5 + 0.55 (7) 0.09 + 0.01 (7) 0.22 + 0.67 (7)2 Swimming 17.9 + 1.8 (7) 0.30 + 0.04 (7) 0.14 + 15 minutes p < 0.05 p < 0.001 0.035 (7)3 Swimming 8.1 + 0.63 (6) 0.18 + 0.02 (7) 0.059 + for 15 min p < 0.05 p < 0.001 0.045 (6) and rest p < 0.001 for 1 h4 Swimming 17.3 + 1.87 (7) 0.25 + 0.06 (6) 0.25 + for 15 min 0.06 (6) and the composition of this invention5 Swimming 9.0 + 0.65 (6) 0.14 + 0.01 (7) 0.136 + for 15 min + p < 0.05 0.009 (7) composition p < 0.0001 of this in- vention and rest for 1 hour______________________________________
TABLE 15______________________________________Effect of the composition of this invention on thecontent of cholesterol in adrenal glands (mg/g), thecontent of glycogen (mg %) and activity of alcoholde-hydrogenase (μmol NADP × H/min/g of the tissue) in theliver of rats under hypokinesia (2 days) Alcoholdehyro-Group of animals Cholesterol Glycogen genase1 2 3 4______________________________________1 Normal 44 + 1.6 3975 + 222 5.04 + 0.2342 Hypokinesia 96 + 2.4 2862 + 251 5.90 + 0.250 p < 0.01 p < 0.004 p < 0.023 Hypokinesia + p < 0.03 p < 0.04 p < 0.01 composition of this invention______________________________________ p in comparison of Groups 1-2 and 2-3
TABLE 16______________________________________Effect of the composition of this invention onsome parameters of the carbohydrate metabolism in ratsGroup of Blood sugar, Liver gly- Blood insulin,animals mg % cogen, mg % μUN/ml1 2 3 4______________________________________Normal diet of ratsNormal 91.0 + 2.7 (9) 4966 + -- 406 (9)Composition 100.5 + 6071 + --of this in- 1.78.sup.x (13) 250.sup.x (10)ventionStarvation for 18 hoursNormal diet (10) 106.8 + 3.7 -- --Starvation (8) 83.8 + 2.0.sup.x -- --Starvation + 106.0 + 4.2.sup.x -- --1 ml/kgof composition ofthis invention30 minutes beforeslaughtering (10)Starvation for 40 hoursNormal diet (10) 116.5 + 5.0 5059 + 452 17.56 + 1.12Starvation (10) 86.0 + 5.0.sup.x 495 + 257.sup.x 9.56 + 0.69Starvation + 91.0 + 5.0 593 + 151 14.5 + 1.0.sup.xcomposition ofthis inventionExcessive diet of ratsWithout composi- 119.0 + 4.3 4966 + 406 22.8 + 2.3sition of thisinvention (10)Composition of this 122.3 + 2.7 6071 + 250.sup.x 17.3 + 1.19.sup.xinvention______________________________________ .sup.x p < 0.05, Composition of this invention is administered intragastrically in the dos of 1 ml/kg twice a day over 5 days. Shown in brackets is the number of animals.
TABLE 17__________________________________________________________________________Activity of β-galactosidase in blood serum of volunteers(nanomol/ml/min, M ± m)__________________________________________________________________________ Aqueous solution of the composition 40% ethanol of this inventionNo. Groups Background 1 hour 2 hours 4 hours background I hour1 2 3 4 5 6 7 8__________________________________________________________________________1 Healthy europeoids 5.95 ± 0.62 6.66 ± 0.21 19.94 ± 1.22.sup.3 35.57 ± 1.63.sup.3 5.72 ± 0.19 5.09 ± 0.27 % of variation 112 335 598 892. Mongoloids 5.77 ± 0.94 5.92 ± 0.68 12.15 ± 0.87.sup.3 12.61 ± 0.98.sup.3 6.89 ± 0.47 6.30 ± 0.33 % of variation 103 211 219 913. Alcoholism 8.79 ± 0.67 21.92 ± 0.94.sup.3 7.98 ± 0.20 10.46 ± 0.91.sup.1 11.72 ± 0.72 11.95 ± 0.83 suffering patients % of variation 249 91 122 102__________________________________________________________________________ Aqueous solution of the composition of this invention NN 40% ethanol + composition of this inventionNo. Groups 2 hours 4 hours background I hour 2 hours 4 hours1 2 9 10 11 12 13 14__________________________________________________________________________1 Healthy europeoids .sup. 4.06 ± 0.44.sup.1 6.85 ± 0.48.sup.1 5.90 ± 0.42 5.78 ± 0.54 6.55 ± 0.42 18.0 ± 1.6.sup.3 % of variation 71 120 98 111 3052. Mongoloids 6.87 ± 0.57 7.50 ± 0.44.sup. 6.33 ± 0.44 9.39 ± 0.71 9.23 ± 0.84 16.4 ± 1.5.sup. % of variation 99 109 148 146 2593. Alcoholism 13.94 ± 0.85 24.26 ± 1.58.sup.3 10.45 ± 0.39 15.15 ± 0.72.sup.2 14.00 ± 0.86.sup.2 12.8 ± 0.9.sup.2 suffering patients % of variation 119 207 145 134 122__________________________________________________________________________ .sup.1 p < 0.05 .sup.2 p < 0.01 .sup.3 p < 0.001
TABLE 18__________________________________________________________________________Variation of the content of hexosamines in human blood serum (mg %), M± m__________________________________________________________________________Groups of 1. Healthy europeoids II Healthy mongoloidsNN volunteers background I hour 2 hours 4 hours background I hour1 2 3 4 5 6 7 8__________________________________________________________________________1. 40% ethanol 72.57 ± 3.55 66.93 ± 4.10 66.00 ± 2.51.sup. 61.20 ± 2.62 48.93 ± 3.31 46.40 ± 1.72.sup. % of variation vs. 92 91 85 95 the background2. 40% ethanol + 53.33 ± 2.39 50.40 ± 3.85 42.53 ± 1.79.sup.2 50.53 ± 3.27 84.60 ± 3.70 63.20 ± 1.21.sup.3 composition of this invention % of variation vs. 95 80 95 75 the background3. Composition 72.16 ± 4.01 94.13 ± 3.92 93.44 ± 4.04.sup.3 .sup. 87.52 ± 1.90.sup.2 36.68 ± 3.71 45.21 ± 3.00.sup.1 of this invention % of variation vs. 131 130 122 127 the background__________________________________________________________________________Groups of II Healthy mongoloids III. Alcoholism-suffering patientsNN volunteers 2 hours 4 hours background I hour 2 hours 4 hours1 2 9 10 11 12 13 14__________________________________________________________________________1. 40% ethanol 48.64 ± 2.93 53.20 ± 3.75 68.30 ± 2.76 .sup. 56.06 ± 2.81.sup.1 54.64 ± 3.43.sup.1 .sup. 57.37 ± 3.32.sup.1 % of variation vs. 99 109 82 80 84 the background2. 40% ethanol + 100.64 ± 3.70.sup.2 93.33 ± 4.22 75.94 ± 4.41 73.71 ± 3.10 66.97 ± 5.37.sup. 70.42 ± 4.16 composition of this invention % of variation vs. 119 110 97 88 93 the background3. Composition .sup. 53.20 ± 1.52.sup.1 .sup. 53.20 ± 2.74.sup.3 60.11 ± 4.81 62.27 ± 3.15 69.94 ± 3.00.sup.1 60.23 ± 3.30 of this invention % of variation vs. 149 149 103 116 100 the background__________________________________________________________________________ .sup.1 p < 0.05 .sup.2 p < 0.01 .sup.3 p < 0.001
TABLE 19__________________________________________________________________________Variation of the content of fractions of neutral lipoids in human bloodserum ofpersons consumed 40% ethanol (in % of the total lipoids, M__________________________________________________________________________± m) I group II groupNN I 2 4 background I hour1 Fractions background hour hours hours 7 8__________________________________________________________________________1. Cholesterol 21.72 ± 1.81 .sup. 27.03 ± 1.32.sup.1 23.06 ± 1.15 23.95 ± 0.90 26.66 ± 1.19 27.89 ± 1.33 esters % of variation 125 106 110 1052. Triglycerides 17.40 ± 0.72 16.53 ± 0.97 19.11 ± 0.75 19.08 ± 0.78 17.45 ± 0.76 16.63 ± 0.86 % of variation 95 110 110 953. Free fatty acids 17.06 ± 0.65 16.88 ± 0.50 15.87 ± 0.42 17.24 ± 0.95 15.10 ± 0.47 16.57 ± 1.08 % of variation 99 93 101 1104. Cholesterol 19.64 ± 0.86 18.25 ± 0.87 19.04 ± 0.24 19.08 ± 0.48 18.54 ± 0.50 17.79 ± 0.26 % of variation 93 97 97 965. Residual 24.18 ± 0.52 24.29 ± 1.85 22.92 ± 0.73 20.65 ± 0.70 22.25 ± 0.31 21.12 ± 0.64 combined fraction__________________________________________________________________________ II group III groupNN 2 hours 4 hours background I hour 2 hours 4 hours1 Fractions 9 10 11 12 13 14__________________________________________________________________________1. Cholesterol 21.22 ± 0.54 29.62 ± 1.44 25.90 ± 2.14 26.47 ± 2.16 22.66 ± 1.05 25.37 ± 2.48 esters % of variation 80 111 102 88 982. Triglycerides 16.48 ± 0.71 19.02 ± 0.22 15.28 ± 1.05 15.40 ± 0.76 16.37 ± 0.69 15.92 ± 1.24 % of variation 94 110 101 107 1053. Free fatty acids .sup. 18.45 ± 0.57.sup.2 13.87 ± 1.15 15.29 ± 1.35 18.64 ± 47.sup.1 .sup. 19.29 ± 16.69 ± 1.99 % of variation 122 92 122 126 1094. Cholesterol 20.04 ± 0.66 17.03 ± 0.71 17.94 ± 0.99 18.71 ± 1.74 21.65 ± 1.96 19.82 ± 0.71 % of variation 108 92 104 121 1115. Residual 23.75 ± 0.97 20.46 ± 0.93 25.60 ± 1.68 20.78 ± 0.81 20.03 ± 1.16 22.13 ± 1.29 combined fraction__________________________________________________________________________ .sup.1 p < 0.05; .sup.2 p < 0.01 Group I healthy europeoids; Group II healthy mongoloids; Group III alcoholismsuffering patients
TABLE 20__________________________________________________________________________Variation of the content of fractions of neutral lipoids in human bloodserum of patients consumedaqueous solution of the composition of this invention (in % of the totallipoids, M ± m)__________________________________________________________________________ Group I Group IINN Fractions background I hour 2 hours 4 hours background I hour1 2 3 4 5 6 7 8__________________________________________________________________________1. Cholesterol 23.07 ± 1.47 22.74 ± 2.10 23.44 ± 0.54 23.10 ± 0.89 23.12 ± 1.32 21.34 ± 1.38 esters % of variation 99 102 101 922. Triglycerides 17.24 ± 0.82 16.75 ± 0.67 20.49 ± 1.29 17.63 ± 0.75 16.79 ± 2.02 18.99 ± 0.47 % of variation 97 119 102 1133. Free fatty acids 16.14 ± 1.20 17.17 ± 0.39 16.85 ± 0.42 17.90 ± 0.63 17.77 ± 1.03 18.05 ± 0.48 % of variation 110 104 111 1024. Cholesterol 17.43 ± 1.57 18.69 ± 1.93 19.97 ± 0.54 17.89 ± 0.93 18.09 ± 0.60 20.33 ± 0.37 % of variation 107 115 103 1125. Residual 26.12 ± 2.30 24.05 ± 1.70 19.25 ± 0.74 23.48 ± 0.71 24.23 ± 1.60 21.29 ± 0.92 combined fraction__________________________________________________________________________ Group II Group IIINN Fractions 2 hours 3 hours background I hour 2 hours 3 hours1 2 9 10 11 12 13 14__________________________________________________________________________1. Cholesterol 23.59 ± 0.54 23.17 ± 0.46 22.49 ± 0.44 24.87 ± 0.54 24.43 ± 0.86 24.05 ± 0.62 esters % of variation 102 100 111 109 1072. Triglycerides 17.73 ± 0.33 18.08 ± 0.56 19.36 ± 1.0 17.16 ± 0.48 17.29 ± 0.39 17.58 ± 0.84 % of variation 106 108 89 89 913. Free fatty acids 16.41 ± 0.67 17.38 ± 0.56 17.77 ± 0.65 17.77 ± 0.55 17.76 ± 0.36 15.05 ± 0.99 % of variation 92 98 100 100 854. Cholesterol 20.51 ± 0.55 20.88 ± 0.44 19.37 ± 0.35 19.39 ± 0.43 18.46 ± 0.79 17.34 ± 0.49 % of variation 113 115 100 95 905. Residual 21.76 ± 0.46 20.49 ± 0.52 21.01 ± 0.61 20.81 ± 0.82 23.06 ± 1.10 25.90 ± 1.13 combined fraction__________________________________________________________________________ Group I healthy europeoids, Group II healthy mongoloids, Group III alcoholism suffering patients.
TABLE 21__________________________________________________________________________Variation of the content of fractions of neutral lipoids in human bloodserum of patients consumeda 40% solution of ethanol (in % of the total lipoids, M ± m) with thecomposition of this invention__________________________________________________________________________ Group 1 Group IINN Fractions background 1 hour 2 hours 4 hours background 1 hour1 2 3 4 5 6 7 8__________________________________________________________________________1. Cholesterol 24.35 ± 2.04 23.91 ± 0.67 22.04 ± 0.41 21.53 ± 0.68 22.30 ± 1.01 24.32 ± 0.55 esters % of variation 98 91 88 1092. Triglycerides 16.41 ± 0.71 18.14 ± 0.30 18.48 ± 1.24 .sup. 19.51 ± 0.69.sup.1 19.95 ± 1.71 18.15 ± 0.55 % of variation 111 113 119 913. Free fatty acids 15.96 ± 0.76 16.19 ± 0.57 16.30 ± 0.26 15.90 ± 0.24 16.12 ± 0.46 16.17 ± 1.10 % of variation 101 102 106 1004. Cholesterol 19.21 ± 0.86 18.87 ± 0.38 18.06 ± 0.84 20.06 ± 1.58 17.84 ± 0.28 18.02 ± 0.93 % of variation 98 94 104 1015. Residual 24.07 ± 1.93 22.89 ± 0.55 24.52 ± 1.61 22.94 ± 1.17 23.79 ± 2.03 23.34 ± 0.60 combined fraction__________________________________________________________________________ Group II Group IIINN Fractions 2 hours 4 hours background I hour 2 hours 4 hours1 2 9 10 11 12 13 14__________________________________________________________________________1. Cholesterol 23.15 ± 1.45 22.89 ± 0.70 24.60 ± 0.59 24.05 ± 0.62 24.26 ± 0.34 22.94 ± 0.90 esters % of variation 104 103 100 101 952. Triglycerides 18.87 ± 2.11 19.47 ± 0.28 17.05 ± 0.52 16.50 ± 0.56 17.43 ± 0.49 18.77 ± 0.66 % of variation 95 98 97 102 1103. Free fatty acids 15.83 ± 0.58 16.95 ± 0.84 15.95 ± 0.53 16.63 ± 0.41 17.00 ± 0.50 17.01 ± 0.52 % of variation 98 105 104 107 1074. Cholesterol 17.66 ± 0.89 19.22 ± 0.45 18.37 ± 0.73 17.85 ± 0.44 19.07 ± 0.42 19.89 ± 0.49 % of variation 99 108 97 104 1085. Residual 24.46 ± 1.45 21.47 ± 1.33 24.03 ± 0.79 24.97 ± 1.08 22.24 ± 1.20 21.39 ± 0.51 combined fraction__________________________________________________________________________ .sup.1 p < 0.01 Group 1 healthy europeoids; Group II healthy mongoloids; Group III alcoholismsuffering patients.
TABLE 22__________________________________________________________________________System ADG-ethanol, in patients consumed solutions of ethanol andcomposition of this invention__________________________________________________________________________ 40% ethanol + composition 40% ethanol of this inventionNN Fractions background I hour 2 hours 4 hours background I hour1 2 3 4 5 6 7 8__________________________________________________________________________1. patients ADG 0.46 ± 0.16 1.24 ± 0.56 1.83 ± 0.58 2.39 ± 0.66 2.28 ± 0.68 3.56 ± 0.662. ethanol 0 0.27 ± 0.01 0.198 ± 0.023 0.113 ± 0.014 0.138 ± 0.0323. mongoloids ADG 2.81 ± 0.97 3.15 ± 0.67 3.17 ± 0.87 3.15 ± 0.89 1.74 ± 0.32 1.69 ± 0.314. ethanol 0.012 ± 0.007 0.174 ± 0.033 0.188 ± 0.024 0.064 ± 0.028 0 0.206 ± 0.0235. healthy ADG 2.90 ± 0.58 1.73 ± 0.29 3.04 ± 0.42 0.52 ± 0.28 2.56 ± 0.23 1.78 ± 0.686. europeoids ethanol 0.023 ± 0.002 0.263 ± 0.028 0.0124 ± 0.013 0.035 ± 0.000035 0.049 ± 0.0004 0.174 ±__________________________________________________________________________ 0.025 40% ethanol + composition of this invention Composition of this inventionNN Fractions 2 hours 4 hours background I hour 2 hours 4 hours1 2 9 10 11 12 13 14__________________________________________________________________________1. patients ADG 1.85 ± 0.39 0.70 ± 0.25 1.06 ± 0.46 0.79 ± 0.27 1.79 ± 0.35 1.67 ± 0.472. ethanol 0.182 ± 0.054 0.203 ± 0.022 0.04 ± 0.012 0.14 ± 0.014 0.076 ± 0.024 0.082 ± 0.0183. mongoloids ADG 2.34 ± 0.87 1.57 ± 0.31 2.48 ± 0.64 1.59 ± 0.58 1.69 ± 0.47 2.37 ± 0.764. ethanol 0.105 ± 0.029 0.103 ± 0.033 0 0 0 05. healthy ADG 2.35 ± 0.57 0.69 ± 0.34 1.00 ± 0.37 1.64 ± 0.40 1.37 ± 0.47 1.27 ± 0.366. europeoids ethanol 0.174 ± 0.016 0.086 ± 0.01 0.006 ± 0.000008 0.042 ± 0.032 0.076 ± 0.035 0.015 ±__________________________________________________________________________ 0.00004 Measurement units: ADG (i/i); ethanol mg %; ADG alcoholdehydrogenase
Under conditions of a double blank control the patients took 40% ethanol with the composition according to the present invention (1:50) or an aqueous solution of this composition. The volume of the taken liquid was 200 ml per 70 kg of the bodymass. The intervals between intakes were 4 days. Blood from vein was taken prior to the liquid intake, 1 hour, 2 and 4 hours thereafter for biochemical investigations. The test results are shown in Tables 17, 18, 19, 20, 21 and 22 hereinbelow.
We have also carried out for 10 months testing of the composition according to the present invention on 8,000 persons. To this end, alcoholic beverages containing the composition according to the present invention were used. The persons included in observations did not take any other alcoholic beverages during the entire period of tests. The total reduction of the alcohol consumption over the period of 10 months constituted 28.01%.
Within 10 months of tests the number of alcoholic psychoses in this group of persons reduced to four cases compared to 12.5 cases on the average over the preceding 6 similar periods.
The course of alcoholic intoxications has also changed: easier hang-over states, a lowered demand for a hang-over drink due to the appearance of somatic complaints inhibiting continuation of heavy-drinking periods in alcohol-abusing persons.
No demographic and social excesses were noted among persons included in observations.
Therefore, on the ground of the studies and experiments conducted a conclusion may be made that the general effect of the composition according to the present invention directed against negative after-effects of the alcohol consumption is composed of the effects provided by the composition ingredients on the maim biological signs of alcohol:
membranotropic effect of ethanol is lowered due to normalization of the membrane stability owing to regulation of the synthesis of cholesterol, its esterification and inclusion into the structure of membranes. This also results in normalization of activity of membrane-combined enzymes and other permeability characteristics according to the principle of Vitamin P--activity;
oxidation of ethanol is effected mainly in the liver with exhaustion of the oxidized form of nicotinamidedinucleotide NAD + . Other oxidizing processes occurring with the use of NAD + are inhibited. The ingredients of the composition according to the present invention act as hydrogen ion acceptors and contribute to lowering of the ratio NADH/NAD + ;
in the cousre of oxidation of ethanol in the organism the most toxic metabolite--acetaldehyde- is formed which when present in tissues is responsible for toxicological and narcotic characteristics of ethanol. The rate of oxidation of ethanol and acetaldehyde depends first of all on activity of alcoholdehydrogenase and acetaldehydedehydrogenase. The ingredients of the composition according to the present invention are capable of lowering the activity of alcoholdehydrogenase by decelarting oxidation of ethanol and, furthermore, of entering into competitive relations with ethanol as a substrate for alcoholdehydrogenase. In doing so, due to conformation of alcoholdehydrogenase there is effected oxidation of not ethanol, but, first of all, of the competiting substrate incorporated in the composition according to the present invention;
calorigenic effect of ethanol, owing to which it is a successful competitor in respect of other sources of energy while being superior to them in the availability criterion. This causes the narrowing of the main metabolic chain of conversion of a number of edible substances due to a competitive alienation of specific dehydrogenases and their prostetic groups. The composition according to the present invention contributes to conservation and, upon a long-time consumption of alcohol, to restoration of other energy supply routs, in particular through gluconeogenesis.
The carried out tests of the composition according to the present invention in experiments on animals, in observation on volunteers have shown that the composition of this invention has an ability of providing rational ways for a high resistance and recovery of the organism. In all cases of extremal loads on animals (of both physical, chemical and biological character) a clearly-pronounced stress-protecting effect is observed. In addition thereto, the composition according to the present invention has specific biological properties of inhibiting the formation of a physical dependence on alcohol and of lowering detrimental effects of its toxic metabolites.
A wide range of a biological action of the composition according to the present invention is explained by the fact that it comprises an indispensible set of substrates ensuring optimal ways of metabolism directed to the preservation of energy resources of the organism by way of synthesis of carbohydrates from non-carbohydrate metabolites through gluconeogenesis.
EXAMPLE 1
A composition contains the following ingredients, mg/g: leukodolphinidine 120, leukocyanidine--80, leukopelargonidine--45, (-)epigallocatechin--42, (±)gallocatechin--31, (-)epicatechin--29, (+)catechin--60, (-)epicatechingallate--18, kaempferol-3-monoglucoside--17, quercetin-3-monoglucoside--22, myricetin-3-monoglucoside--14, quercetin-3-glucoside--24, astragalin--13, lignin--75, D-glucose 83.6, D-fructose--64, saccharose--33,5, raffinose--24, arabinose--25, xylose--31.6, pectine--20, lysine--3.4, histidine--0.2, arginine--0.4, aspartic acid--4.3, threonine--1.1, serine--2.0, glutamic acid--3.0, proline--3.3, glycine--2.2, alanine--3.8, cystine--0.3, valine--1.8, methionine--0.4, isoleucine--0.8, leucine--2.8, tyrosine--0.5, phenylalanine--0.3, tartaric acid--4.2, malic acid--3.8, citric acid--4.0, ascorbic acid--4.0, α-ketoglutaric acid--1.9, fumaric acid--2.1, galacturonic acid--2.2, glyceric acid--1.8, glycolic acid--1.7, glycouronic acid-3.0, oxalic acid--2.3, succinic acid--5.0, shikimic acid--3.0, α-amyrine--0.4, β-amyrine--0.4, loupeol--0.3, taraxasterol--0.4, taraxerol--0.4, germanicol--0.3, obtusifoliol--0.8, citrostadienol--0.7, β-cetosterine--3.2, stigmasterol--1.0, kaempesterol--0.8, oxymatairesinol--2.9, matairesinol--2.3, pinoresinol--2.5, liovyl--2.7, isolariciresinol--2.7, olivyl--1.9, querinol arabinoside--6.2, querinol xyloside--3.8, paraoxybenzoic acid--1.2, protocatechinic acid--3.5, gallic acid--1.9, vanillic acid--4.3, syringe acid--4.1, vanilline--1.5, syringe aldehyde--1.3, sinapic aldehyde--0.9, coniferyl aldehyde--1.3, cotadecanolferulate--1.5, eicosanolferulate--1.4, docosanolferulate 1.1, tetracosanolferulate--0.5, hexacosanolferulate--0.5.
This composition in the amount of 5 g is dissolved in 100 ml of a 40% aqueous-alcoholic solution.
The resulting aqueous-alcoholic solution has a red-brown colour, a weak characteristic scent and a soft astringent taste. The solution has a low toxicity. The LD 50 is 36.5 ml/1,000 g of bodymass of a rat. The solution is capable of providing rational ways for resistance and recovery of the organism, suppresses the formation of a physical dependence on alcohol and lowers detrimental effects of its toxic metabolites.
EXAMPLE 2
A composition contains the ingredients similar to those sepcified in Example 1 in the following amounts, mg/g: leukoanthocyanes--197.1, catechins--137.7, flavanols--72.9, lignin--61.2, reducing sugars--410.76, pectin--16.2, free aminoacids--24.3, organic acids--32.4, sterols, methylsterols, dimethylsterols--1.78, lignans--12.1, lignan glycosides--8.1, phenolic acids--12.1, phenolic aldehydes--4.05, alkylferulates--4.05.
This composition in the amount of 5 g is dissolved in 100 ml of a 40% aqueous-alcoholic solution. The resulting aqueous-alcoholic solution has a red-brown colour, a weak specific scent and a soft slightly sweet astringent taste. The solution has a low toxicity: the LD 50 is 41.2 ml/1,000 g of bodymass of a rat.
The solution has an ability of ensuring rational ways for resistance and recovery of the organism, it slightly inhibits the formation of a physical dependence on alcohol and reduces, to a certain extent, negative effects of its toxic metabolites; the composition has a low activity which is even not recorded in a number of biological tests.
EXAMPLE 3
A composition contains the ingredients similar to those specified in Example 1 hereinbefore in the following amounts, mg/g: leukoanthocyanes--219, catechins--153, flavanols--81, lignin--68, reducing sugars--345.17, pectin--18, free aminoacids--27, organic acids--36, sterols--4.5, methylsterols--1.35, dimethylsterols--1.98, lignans--13.5, lignan glycosides--9, phenolic acids--13.5, phenolic aldehydes--4.5, alkylferulates--4.5.
This composition in the amount of 5 g is dissolved in 100 ml of a 40% aqueous-alcoholic solution. The resulting solution is of a red-brown colour, it has a weak specific scent and a soft astringent taste. The solution has a low toxicity: its LD 50 is 36.5 ml/1,000 g of bodymass of a rat.
The solution is capable of providing rational ways for resistance and recovery of the organism; it inhibits the formation of a physical dependence on alcohol and slightly lowers negative effects of its toxic metabolites.
EXAMPLE 4
A composition contains the ingredients similar to those specified in Example 1 hereinbefore in the following amounts, mg/g: leukoanthocyanes--270, catechins--187, flavanols--99, lignin--83, reducing sugars--197.5, pectin--22, free aminoacids--33, organic acids--44, sterols--5.5, methylsterols--1.65, dimethylsterols--2.42, lignans--16.5, lignan glycosides--11, phenolic acids--16.5, phenolic aldehydes--5.5, alkylferulates--5.5.
This composition in the amount of 5 g is dissolved in 100 ml of a 40% aqueous-alcoholic solution. The resulting solution has a red-brown colour, a weak specific scent and a soft astringent taste. The solution is of a low toxicity: its LD 50 is 36.5 ml/1000 g of bodymass of a rat.
The solutions is capable of ensuring rational ways for resistance and recovery of the organism, inhibits the formation of a physical dependence on alcohol and lowers negative effects of its toxic metabolites.
EXAMPLE 5
A composition contains the ingredients similar to those of Example 1 in the following amounts, mg/g: leukoanthocyanes--297, catechins--205, flavanols-109, lignin--91, reducing sugars--120.6, pectin-24, free aminoacids--36, organic acids--48, sterols--6, methylsterols--1.8, dimethylsterols-2,6, lignans--18, lignan glycosides--12, phenolic acids--18, phenolic aldehydes--6, alkylferulates--6.
This composition in the amount of 5 g is dissolved in 100 ml of a 40% aqueous-alcoholic solution. The resulting solution has a red-brown colour, a pronounced specific odour and an astringent taste. The solution has a low toxicity: its LD 50 is 33.3 ml/1,000 g of bodymass of a rat.
The solution is capable of ensuring rational ways for resistance and recovery of the organism; it inhibits the formation of a physical dependence on alcohol and diminishes detrimental effects of its toxic metabolites. | 4y
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is related to a streetlight power controller, and more particularly to a streetlight power controller simplifying wiring procedure and ensuring to constantly turn on streetlight under thunder and lighting in the nighttime.
[0003] 2. Description of the Related Art
[0004] With reference to FIG. 7 , a conventional streetlight power controller has a control box 70 and a photosensing device 80 . The control box 70 has a power switch (not shown) mounted therein. The photosensing device 80 is electrically connected with the power switch inside the control box 80 by using power wires and sends a sensed luminance level of ambient light to the power controller inside the control box.
[0005] The control box 70 has three power cables. Two of the power cables are connected with the power lines 61 (R, N) of a streetlight 60 , and the remaining one is connected with photosensing device 80 . Similarly, the photosensing device 80 has three power wires. One of the power wires is connected with the control box 70 . The rest of two power wires are connected with the power lines 51 (S, N) of a utility pole 50 . The control box 70 acquires the power from the power lines 51 of the utility pole through the photosensing device 80 . The power is not outputted to the control box 70 unless the luminance level of ambient light sensed by the photosensing device is low. The power switch in the control box further transmits the power to the power lines 61 of the streetlight 60 to turn on the streetlight 60 . Hence, when ambient light is bright, the control box 70 receives no power from the power lines 51 and the streetlight 60 goes off.
[0006] To acquire the power of the power lines 51 of the utility pole 50 , the control box 70 must be connected with the power lines of the streetlight 60 and the photosensing device 80 must be connected with the power lines 51 of the utility pole 50 . Therefore, installation workers must carefully pay attention to the wiring correctness. Besides, for sake of being independent devices, the control box 70 and the photosensing device 80 need to be separately fixed on the streetlight pole with a fixing member. With reference to FIG. 8 , the photosensing device 80 is fastened on a streetlight pole in collaboration with an inverted-L fixture and the control box 70 is separately fastened on a streetlight pole with screw. Accordingly, an installation worker must separately fix the control box 70 and the photosensing device 80 on the streetlight pole first, then connect the three power wires of the photosensing device with the power lines of the utility pole and the corresponding power cables of the control box 70 , and connect the remaining power cables of the control box 70 with the power lines of the streetlight 60 . All installation procedures are complicated, time consuming and do not allow to make mistake to the wiring connection.
[0007] Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
[0008] A first objective of the present invention is to provide a photosensing power controller for streetlight capable of simplifying installation procedures.
[0009] To achieve the foregoing objective, the photosensing power controller for streetlight has a control box and a photosensing device.
[0010] The control box has a body, a socket, two sets of power cables and a power switch. The socket is mounted on the body. The two sets of power cables are mounted through the body. The power switch is mounted inside the body, is electrically connected with the socket and the two sets of power cables, and has a trigger terminal.
[0011] The photosensing device is plugged in the socket of the control box, is electrically connected with the trigger terminal and one set of power cables through the socket, and triggers to switch the power switch in accordance with a luminance level of ambient light.
[0012] The socket is mounted on the body and is directly and electrically connected with the power switch inside the control box. Installation workers only need to plug in the photosensing device on the control box in advance and fix the control box on the streetlight pole and further correctly connect the power cables of the control box with the power lines of the utility pole and the streetlight, thereby effectively reducing the procedures and labor of the installation.
[0013] A second objective of the present invention is to provide an uninterruptible photosensing power controller for streetlight.
[0014] The photosensing device of the uninterruptible photosensing power controller for streetlight has a relay. The relay has a first switch and a second switch. During nighttime, the first and second switches are switched on while the current from the utility pole flows through the first switch without going through the second switch connected with a resistor. When the first switch is damaged by a surge, the second switch provides a backup path to supply power to the streetlight through the first switching unit. The aforementioned power switch further has a second switching unit. The second switching unit has a transfer switch, a normally-open line and a normally-closed terminal. The transfer switch is connected with the trigger terminal and is activated by the first excitation coil of the power switch to selectively connect with the normally-open line or the normally-closed terminal. The control box further has a third switching unit. The third switching unit has a third excitation coil connected with the normally-open line of the second switching unit and a third switch connected between the two sets of power cables.
[0015] When the first excitation coil of the power switch breaks down, the third switch is activated to switch on through the second switching unit and provide a path to supply power to the streetlight. Accordingly, even if subjected to thunder and lightening and faulty conditions, the present invention can be continuously triggered to light up the streetlight.
[0016] Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a partially exploded view of a first embodiment of an uninterruptible photosensing power controller for streetlight in accordance with the present invention;
[0018] FIG. 2 is a perspective view of the uninterruptible photosensing power controller for streetlight in FIG. 1 ;
[0019] FIG. 3 is a schematic view of the uninterruptible photosensing power controller for streetlight in FIG. 1 connected with a utility pole and a streetlight;
[0020] FIGS. 4A to 4C are detailed circuit diagrams of the uninterruptible photosensing power controller for streetlight in FIG. 1 ;
[0021] FIG. 5 is a front view of a second embodiment of an uninterruptible photosensing power controller for streetlight in accordance with the present invention;
[0022] FIGS. 6A to 6D are detailed circuit diagrams of the uninterruptible photosensing power controller for streetlight in FIG. 5 ;
[0023] FIG. 7 is a schematic view of a conventional power controller for streetlight connected with a utility pole and a streetlight; and
[0024] FIG. 8 is a side view of the conventional power controller for streetlight in FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
[0025] With reference to FIGS. 1 to 3 , a first embodiment of an uninterruptible photosensing power controller for streetlight in accordance with the present invention has a control box 10 and a photosensing device 20 .
[0026] The control box 10 has a body 11 , a socket 12 , two sets of power cables (S, R, N) and a power switch 30 . The socket 12 is mounted on a top of the body and the power cables (S, R, N) are mounted through the body 11 . In the first embodiment, the socket 12 has three plug holes 121 . One set of power cables (S, N) is adapted to connect with power lines 51 of a utility pole 50 . The other set of power cables (R, N) is adapted to connect with power lines of a streetlight. The socket 12 is electrically connected with a trigger terminal (I/P) of the power switch 30 and the set of power cables (S, R, N) connected to the streetlight 60 .
[0027] The photosensing device 20 is plugged in the socket 12 of the control box 10 and is electrically connected with the trigger terminal (I/P) of the power switch 30 through the socket 12 and triggers the power switch 30 to switch on or off in accordance with a luminance level of ambient light. In the first embodiment, the photosensing device 20 has three blades 201 to correspond to the three plug holes 121 and the three blades 201 are plugged in the three plug holes 121 of the socket 12 .
[0028] With reference to FIG. 4 , the photosensing device 20 has a relay and a photovaristor 21 . The relay has an excitation coil 212 , a first switch S 1 and a second switch S 2 . The first switch S 1 and the second switch S 2 are parallelly connected between the power line S connected to the utility pole and the excitation coil 212 and connected with the trigger terminal I/P of the power switch 30 . The second switch S 2 is serially connected with a resistor R. The photovaristor 21 is serially connected between the S line of the set of power cable connected to the utility pole and the N line of the set of power cable connected to the streetlight 60 through a resistor 211 and the excitation coil 212 of the relay.
[0029] The power switch 30 has a first switching unit 32 and a first excitation coil 31 . The first switching unit 32 is connected across the S line of the set of power cable connected to the utility pole and the R line of the set of power cable connected to the streetlight 60 . One end of the first excitation coil 31 is connected with the trigger terminal I/P and is connected with the first switch S 1 and the second switch S 2 of the photosensing device 20 . The first switching unit 32 is switched on by a current outputted from the first switch S 1 or the second switch S 2 and flowing through the first excitation coil 31 .
[0030] During daytime, the photovaristor 21 has a low resistance value (below 50Ω) due to the bright luminance. The excitation coil 212 of the relay is induced so that the first switch S 1 and the second switch S 2 switch off. Hence, the set of power cable 51 of the utility pole 50 is disconnected from the first switch S 1 and the second switch S 2 . Meanwhile, the first excitation coil 31 of the power switch 30 has no current flowing in, the first switching unit 32 switches off, and the set of power cable connected to the streetlights 60 is disconnected. As a result, the streetlights 60 go off.
[0031] With reference to FIG. 4B , during nighttime, the photovaristor 21 has a high resistance value (1MΩ) due to the deficient luminance. The first switch S 1 and the second switch S 2 of the relay simultaneously switch on. As the second switch is serially connected with the resistor R, a current from the utility pole flows to the trigger terminal I/P of the power switch 30 through the first switch S 1 instead of the second switch S 2 . The first excitation coil 31 of the power switch then activates the first switching unit 32 to switch on to connect to the power cable connected to the streetlight 60 . The power of the utility pole is outputted to the streetlight and the streetlight turns on.
[0032] With reference to FIG. 4C , when the current of the power of the utility pole 50 increases due to a thunder and lightening in the nighttime, the first switch S 1 breaks down but the second switch S 2 remains to be on as an alternative power input path. A current flowing through the first excitation coil 31 continuously activates the first switching unit 32 to switch on. Therefore, the power from the utility pole is outputted to the streetlights 60 through the first switching unit 32 .
[0033] With reference to FIGS. 5 and 6A , a second embodiment of an uninterruptible photosensing power controller for streetlight in accordance with the present invention has a photosensing device 20 and a control box 10 a.
[0034] The photosensing device 20 is the same as that of the first embodiment. The control box 10 a is similar to that of the first embodiment except that the power device 30 a further has a second switching unit 33 and the control box 10 a further has an third switching unit 40 . The second switching unit 33 has a transfer switch 331 , a normally-open terminal NO and a normally-closed terminal NC. The transfer switch 331 is also activated by the first excitation coil 31 of the power switch 30 a to selectively connect with the normally-open terminal NO or the normally-closed terminal NC. The third switching unit 40 has a third excitation coil 41 and a third switch 42 . One end of the third excitation coil 41 is connected with the normally-open terminal NO of the second switching unit 33 , and the other end is connected with the N line of the set of power cable connected to the streetlight 60 . The third switch 42 is connected across the S line of the set of power cable connected to the utility pole and the R line of the set of power cable connected to the streetlight 60 .
[0035] With reference to FIGS. 3 and 6A , the second embodiment of the uninterruptible photosensing power controller for streetlight is operated in the daytime. Because the resistance value of the photovaristor 21 is low, the power of the utility pole 50 is not inputted to the first excitation coil 31 of the power switch 30 a , the first switching unit 32 is not switched on, and the transfer switch 331 of the second switching unit 33 is connected with the normally-open line NO. Accordingly, the streetlights 60 go off.
[0036] With reference to FIG. 6B , during nighttime, the resistance value of the photovaristor 31 increases and the current of the utility pole 50 is inputted to the first excitation coil 31 of the power switch 30 a through the first switch S 1 . Thus, the first switching unit 32 is switched on, the power from the utility pole 50 is outputted to the streetlights 60 , and the streetlights turn on. Meanwhile, the transfer switch 331 of the second switching unit 33 is activated by the first excitation coil 31 to connect with the normally-closed terminal NC and protect the power through the first switch from flowing in the streetlights 60 through the third switch 40 , so that the second switching unit can be continuously switched on.
[0037] With reference to FIG. 6C , when the power of the utility pole 50 encounters a surge due to thunder and lightening and the first switch S 1 breaks down, the second switch S 2 remains intact due to the resistor R and switches on, and the transfer switch 331 of the second switching unit 33 is activated by the first excitation coil 31 to connect with the normally-closed terminal NC. Meanwhile, the current of the utility pole 50 is outputted to the first excitation coil 31 of the power switch 30 a through the second switch S 2 , and the first switching unit 32 is switched on. Therefore, the power of the utility pole 50 is outputted to the streetlight 60 through the first switching unit 32 , and the streetlight turns on. As the transfer switch 331 is connected with the normally-closed terminal NC, the power of the utility pole 50 is protected from flowing in the streetlight 60 through the third switch 40 so that the first switching unit 32 can be continuously switched on and the transfer switch 331 of the second switching unit 33 can be continuously connected with the normally-closed terminal NC.
[0038] With reference to FIG. 6D , when the first excitation coil 31 of the power switch 30 a breaks down, the transfer switch 331 is connected with the normally-open terminal NO for sake of the unavailable first extraction coil 31 . When the power of the utility pole 50 is outputted to the third excitation coil 41 through the first switch S 1 and the second switching unit 33 , the third switch 42 is activated by the third excitation coil 41 to switch on, the power from the utility pole is outputted to the streetlights 60 through the third switch 42 , and the streetlights 60 turn on.
[0039] Given the socket 12 mounted on the control box 10 and electrically connected with the power switch 30 inside the control box 10 , the photosensing device 20 can be directly plugged in and fixed on the control box 10 , and electrically connected with the power switch 30 inside the control box 10 . Consequently, installation workers only need to mount the photosensing device 20 on the control box 10 beforehand and fix the control box on the streetlight pole. Furthermore, installation workers just need to correctly connect the power cables of the control box 10 with the power lines of the utility pole 50 and the streetlight 60 , thereby effectively simplifying the process and reducing labor of the installation. Moreover, the first switch S 1 of the relay inside the photosensing device 20 is parallelly connected with the second switch S 2 serially connected with a resistor. After the first switch S 1 is damaged by a surge current, the second switch S 2 provides a backup path to supply power to the streetlight 60 through the first switching unit 32 . When the first excitation coil 31 of the power switch 30 a breaks down, the power from the utility pole 50 flowing through the normally-open terminal NO of the second switching unit 33 activates the third switch 40 to switch on and supplies power to the streetlights 60 through the third switch 40 . Accordingly, even if subjected to thunder and lightening and faulty conditions, the present invention can be continuously lighted up to safeguard passersby.
[0040] Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only. Changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | 4y
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RELATED APPLICATIONS
This application is a continuation-in-part of Ser. No. 630,977, filed Nov. 12, 1975 and now abandoned.
BACKGROUND AND SUMMARY OF INVENTION
Composites of nickel and alumina are well known and widely used catalysts for the hydrogenation of carbon monoxide and/or carbon dioxide to produce methane-rich product gases. The process is generally referred to as methanation, and is highly exothermic in nature. One problem of great concern encountered in such methanation processes relates to the extreme sensitivity of nickel catalysts to poisoning by sulfur compounds, usually H 2 S. This sensitivity has in the past necessitated the use of guard chambers to remove trace amounts of sulfur compounds from the feed gases, and/or other expensive sulfur removal processes for pretreating the feed gases. In general, in order to insure acceptable catalyst life, it is necessary to reduce the sulfur content of the feed gas to less than 1 ppm H 2 S, and according to some authorities to less than 0.005 grains of sulfur per 1000 cubic feet of gas, which is less than 0.008 vppm (Catalysis, Vol. IV, Emmett ed. Reinhold Publishing Co. 1956 p.506). This problem is further aggravated by the fact that sulfur poisoning of nickel methanation catalysts has heretofore been regarded as irreversible, the sulfur-poisoned catalyst being non-regenerable. (Richardson, J. T., "SNG Catalyst Technology", Hydrocarbon Processing, December 1973, page 94; Catalysis Vol IV supra pp 504-506).
It has been firmly established that the active species of nickel for methanation is metallic nickel. The sulfur poisoning of conventional nickel methanation catalysts is attributable mainly to conversion of the active metallic nickel to inactive sulfides such as NiS. The non-regenerability of the poisoned catalysts arises because of the practical impossibility of reducing the nickel sulfide back to metallic nickel with hydrogen at temperatures below those at which sintering of the nickel occurs, i.e. below about 1500° F.
In U.S. Pat. No. 2,697,078 a nickel oxide catalyst employed for hydrodesulfurization is said to be regenerable by hydrogen reduction at 900° F, and it is speculated that in addition to removing deactivating coke deposits, the regeneration also effects the reduction: NiS + H 2 → Ni + H 2 S. However, as will be shown hereinafter, this reduction does not occur to any significant degree, and it must hence be concluded that the reported regeneration was due solely to the removal of deactivating coke or other deposits. It is now well established that nickel sulfide itself is very active for hydrodesulfurization.
U.S. Pat. No. 2,393,909 discloses a synthesis (Fischer-Tropsch) process utilizing a Group VIII metal catalyst, iron, cobalt and nickel being mentioned. The catalyst, after becoming deactivated by deposits of hydrocarbons, sulfur, carbon, etc. is said to be regenerable by stripping with hydrogen at undisclosed temperatures. The hydrogen is said to remove sulfur as hydrogen sulfide, and to physically or chemically strip hydrocarbonaceous materials from the catalyst. Here again, it must be presumed that any regeneration obtained was due to the removal of hydrocarbonaceous deposits and/or the hydrogenation of organic sulfur associated with such deposits, since none of the sulfides or iron, cobalt or nickel are reducible to the free metal under feasible reducing conditions. The principal and preferred catalyst disclosed for the synthesis reaction, iron, is well known to be much less sensitive to sulfur poisoning than is nickel (Catalysis, Vol. IV supra, p. 506).
In view of the practical irreducibility of nickel sulfide, and the established requirement for free metallic nickel in active methanation catalysts, the regeneration achieved herein is very surprising. The explanation is believed to be related to a unique characteristic of the present catalysts, which distinguishes them from prior art catalysts, namely their relatively low specific nickel surface area, ranging between about 5 and 50 m 2 /g of Ni. Known prior art methanation catalysts exhibit a relatively high specific nickel surface area, ranging upward from about 60 m 2 /g of Ni. This can only mean that a larger proportion of the nickel in the original fresh catalysts of this invention is in a catalytically inactive form, as compared to prior art catalysts.
The inactive form of nickel in the fresh catalysts utilized herein comprises at least in part, nickel aluminate, as determined by electron diffraction studies. This inactive form of nickel does not combine with sulfur, and it is postulated that during regeneration it is slowly reduced to form fresh metallic nickel, the sulfided nickel remaining in the catalyst as an inert component. This "reservior" of inactive, non-sulfided, but recoverable nickel apparently is a distingushing characteristic of the present catalysts. Prior art catalysts appear to be lacking in this reservior, which could account for the fact that they regain at best only a very transient recovery of activity upon hydrogen reduction.
It should not be concluded from the foregoing that regenerability of the present catalysts is achieved only by sacrificing activity normally associated with high specific surface areas of active metal. It has been found that the methanation reaction does not require high catalytic surface areas. For catalysts containing between about 15 and 60 weight percent of Ni, very little improvement in efficiency is obtained by providing more than about 10 m 2 /g of nickel specific surface area. As used herein, the term "specific surface area" refers to surface area per gram of Ni, as determined by hydrogen chemisorption after reducing the fresh calcined catalyst in hydrogen for 16 hours at 700° F, as described in J.A.C.S., 86, page 2996 (1964). The actual hydrogen chemisorption is measured by the Flow method described in J. Catalysis, 9, page 125 (1967).
DETAILED DESCRIPTION
Catalysts having the desired characteristics of surface area, thermal stability, and regenerability required herein are best prepared by a gradual coprecipitation technique wherein basic compounds of aluminum and nickel are gradually and homogeneously coprecipitated from an aqueous solution over a period of time ranging between about 30 minutes and 24 hours or more. According to this procedure, water soluble salts, e.g. nitrates, acetates, sulfates, of aluminum and of nickel, in the proportions desired in the final catalysts, and a delayed precipitant such as urea, are dissolved in water at a relatively low temperature to provide a homogeneous solution. The proportion of urea should be sufficient to provide upon hydrolysis thereof an amount of NH 4 OH sufficient to precipitate all metal salts in solution as hydroxides. The solution is then heated to temperatures of e.g., 80°-110° C to effect gradual hydrolysis of urea. As hydrolysis proceeds, the urea gradually decomposes into ammonia and carbon dioxide, with resultant gradual raising of the pH of the solution. When the solution reaches about pH 4.5, some precipitation usually begins, and proceeds continuously until completed at about pH 6-7.5. It is important not to allow the pH to rise above about 8.0, for at higher pH's soluble ammonia complexes of nickel begin to form. Upon completion of coprecipitation, the coprecipitate is recovered in conventional manner as by filtration, washing and drying.
At this point it is normally desirable to shape the partially dried coprecipitate into the form desired, as by extrusion, pelleting, casting or the like. The shaped particles are then subjected to calcination at temperatures between about 700° and 1200° F for period ranging between about 1-12 hours or more. Catalysts prepared by this or other suitable delayed coprecipitation techniques, display the following herein desired characteristics:
______________________________________ Preferred Broad Range Range______________________________________Wt. % NiO (as Ni) 15-60 25-50Total BET Surface Area,m.sup.2 /g 75-300 100-250Specific Ni Surface Area,m.sup.2 /g of Ni 5-50 10-35______________________________________
Final activation of the catalyst for use in methanation is carried out, usually after the catalyst is placed in the reactor, by reduction in a flowing stream of hydrogen at temperatures of 500°-1200° F. Activation is complete when the off-gases become substantially free of water vapor.
Catalysts of the above description show outstanding utility per se in catalyzing the hydrogenation of carbon oxides to produce methane. This process is generally carried out at temperatures ranging between about 600° and 1500° F, pressures between about 100-1500 psig, and at gas hourly space velocities ranging between about 3000 and 15000 V/V/Hr. Typically, the feed gases may contain about 10-40 volume percent CO and 40-60 volume percent H 2 , on a dry basis. The methanation reaction is extremely exothermic, and much difficulty has been encountered in controlling temperature rise in the reactor. One widely used technique under adiabatic conditions involves the recycle of large volumes of product gas (mainly methane) to serve as a heat sink, thus adding greatly to operating costs.
A less expensive approach to temperature control involves conducting the methanation in two or more adiabatic stages, with intervening cooling of the reactant gases. In the first of such stages, it would be very desirable to initiate the reaction at low temperatures of e.g. 500°-700° F and allow the exothermic temperature rise to level out at e.g. 1350°-1500° F, at which temperature equilibrium limitations substantially suppress further exothermic reaction. The exit gases are then cooled to e.g. 600°-950° F and passed into a second stage in which more favorable equilibrium peak temperatures of e.g. 1100°-1250° F are reached. Further completion of the reaction can be achieved in a third stage operating at inlet temperatures of e.g. 500°-650° F and peak temperatures of e.g. 750°-850° F. At the latter temperatures, thermodynamics permit the methanation reaction to go to 95-98% completion.
Previously available methanation catalysts do not permit of taking maximum advantage of the above multi-stage operation. At any given methanation temperature, catalyst life is a problem. Some catalysts are fairly stable at the lower temperatures, but unstable at the high temperatures. No catalyst has yet been found which can maintain its activity over the wide temperature range desired in the first stage operation described above. The only known catalysts which are sufficiently stable at temperatures above about 1100°-1200° F rapidly become inactive for low-temperature methantion, to the extent that they will not initiate the reaction at temperatures below about 1200° F. As a consequence, it has been found necessary to carry out such first-stage operations with inlet gas temperatures above 1200° F, thereby markedly decreasing efficiency. The catalysts of this invention however are found to be remarkably stable over the entire temperature range of 500°-1500° F, and may hence be employed efficiently in any of the foregoing methanation processes.
Regardless of the particular methanation technique utilized, the problem of sulfur poisoning of the catalyst is likely to arise. As noted above, rapid poisoning of the catalyst takes place unless the sulfur content of the feed gases is maintained below 1 ppm, and preferably below 0.5 ppm. Available techniques for reducing the sulfur content of typical feed gases to these low levels are very expensive and subject to periodic upset conditions, such that a considerable portion of the catalyst bed may become deactivated before desulfurization conditions can be stabilized. The regeneration technique of this invention can be conveniently utilized to reactivate catalysts deactivated as a result of feed gas desulfurization upsets, or which have purposely been allowed to deactivate in order to economize on feed desulfurization costs.
Reactivation of the sulfur poisoned catalyst is carried out by extended, high temperature reduction with a flowing stream of reduction gas consisting essentially of hydrogen, which may or may not be diluted with inert gases. Obviously, the reduction gas should be essentially completely free of sulfur compounds; no more than about 0.5 ppmv of H 2 S should be present. Reduction gas flow rates in the range of about 1000-10,000 GHSV will give some effective reactivation in 5 hours at temperature of 1000-1500° F. However, in most cases it will be necessary to extend the reduction time to at least about 12 hours, and sometimes up to about 200 hours for complete reactivation. Obviously, the extent to which the catalyst has been deactivated will have an important bearing on the severity and time required to achieve complete recovery of activity. In general however, operative reaction conditions can be summarized as follows:
______________________________________Reactivation Conditions Broad Range Preferred Range______________________________________H.sub.2 Flow Rate, GHSV 1000 - 10,000 2000 - 8,000Temperature, ° F 800 - 1500 900 - 1200Time, Hrs. 5 - 200 50 - 1500______________________________________
As will be shown hereinafter, reactivation under the above conditions converts essentially none of the nickel sulfide to metallic nickel, and removes less than 25%, usually less than about 20% of the total sulfur content as H 2 S. However, the nickel specific surface area is substantially increased.
In most cases, the reactivation can be improved by flowing the reduction gas through the catalyst bed in an opposite direction from the previous flow of feed gases. This procedure is most effective in cases where the feed inlet portion of the catalyst bed has become more heavily sulfided than the downstream portions thereof. In this manner, any H 2 S generated from labile sulfur deposits on the catalyst does not contact the relatively unsulfided portion of the catalyst bed.
The following examples are cited to demonstrate effectiveness of the process, but are not to be construed as limiting in scope:
EXAMPLE 1
Catalyst Preparation
A catalyst of this invention, designated A, was prepared as follows:
About 8730 grams of Ni(NO 3 ) 2 .6H 2 O was dissolved in 15,000 ml H 2 O, and 11,250 grams of Al(NO 3 ) 3 .9H 2 O was dissolved in 12,000 ml H 2 O to which another 3000 ml of H 2 O was added after mixing the two salt solutions in a 25-gallon steam-jacketed stainless-steel kettle equipped with stirrer and thermometer. A third solution consisting of 4800 grams of urea in 15,000 ml H 2 O was then added to the kettle. The total volume of solution in the kettle was about 15.4 gallons.
The solution was heated by introducing 15 pound steam into the kettle jacket. Vigorous stirring was used to obtain rapid heat transfer; heat-up to 209° F required about 1 hour. At this temperature, rapid evolution of CO 2 occurred due to urea hydrolysis. After about four hours at 209°-210° F the pH had risen from about 2.3 to 4.5, at which point some precipitation had started. Urea hydrolysis was allowed to continue, the pH rising to 5.3 in 85 more minutes where it remained for about two hours before slowly rising to about 6.0 during the next 2.5 hours. The slurry was then allowed to cool overnight before discharge from the kettle and filtering.
A sample of filtrate was analyzed for nickel by X-ray fluorescence and found to contain 3.6 mg Ni/ml. Since a total of 29 liters of filtrate was collected, 104.4 grams of nickel out of 1750 grams taken had not precipitated, or about 6% of the total. A sample of filtrate was heated at 95° C for another 24 hours and further precipitation occurred. This shows that loss of nickel can be substantially eliminated by longer digestion time or by using slightly more urea, so that the final pH is close to 7 (but below about pH 8, where soluble ammonia complexes begin to form).
After a final water wash, the filter cake was dried at 250° F to an LOI of 32.2%. It was ground to a fine powder in a hammer mill, dry-ground in a muller for 2 hours, then wet-mulled to an extrudable paste. The paste was then extruded through a 1/16 inch die, air dried, and calcined at 900° F for 3 hours. The finished catalyst contained 44% Ni and had a total surface area of 184 m/ 2 /g.
After reducing for 16 hours at 700° F in 100% H 2 as described in J.A.C.S. 86 p. 2996 (1964), the catalyst was found to have a nickel specific surface area of 18.9 m 2 /g of Ni, as measured by the Flow method described in J.Catalysis, 9, p. 125 (1967).
EXAMPLE 2
Activity Testing
Catalyst A of Example 1 was tested for methanation activity, along with a comparison Catalyst B. Catalyst B was a commercial Ni--Al 2 O 3 methanation catalyst prepared by conventional, rapid coprecipitation, containing about 45-50 wt.% Ni, and having a nickel specific surface area of about 70-80 m 2 /g of Ni. The conditions of the test procedure were as follows:
______________________________________Feed Gas Composition:H.sub.2 30.9 vol.%CH.sub.4 9.6CO 7.9CO.sub.2 7.9H.sub.2 O 43.7Inlet Temperature 900° FOutlet Temperature 1220° F (Calculated Adiabatic)Pressure 300 psigCatalyst Volume 85 ml (13" bed length)GHSV 10,000______________________________________
Since the reactor was heated in a fluidized sand bath, reaction conditions were not adiabatic, but quasi-isothermal. Typically, the peak temperatures were 1150°-1175° F, dropping to about 925° F at the outlet as a result of cooling by the sand bath. The equilibrium composition established at the lower temperature corresponds to approximately 98% conversion of CO.
Seven thermocouples were placed in the upper portion of the catalyst bed, the first about 1/2 inch below the top of the bed, and the remainder spaced about 1/2 inch apart down the bed. By this arrangement the catalyst deactivation rate can be observed as the peak temperature travels slowly down the bed, reflecting progressive catalyst deactivation. Also, the difference in temperature (ΔT) between successive thermocouples reflects the amount of reaction occurring over the respective intervals between thermocouples. A negative ΔT indicates that the reaction has already gone essentially to equilibrium, permitting cooling by the sand bath to take place. At the end of 6 days, the respective temperatures were as follows:
TABLE I______________________________________ Temperatures Prior to Introduction of H.sub.2 S, ° F ΔT from Feed Inlet or Feed Inlet from Preceding Thermo- 900° F couple, ° FThermocouple Cat A Cat B Cat A Cat B______________________________________1 1145 1155 245 2552 1155 1150 10 -53 1135 1125 -20 -254 1120 1112 -15 -135 1102 1090 -18 -226 1080 1072 -22 -187 1060 1052 -20 -20______________________________________
The foregoing shows that, in the absence of sulfur, each catalyst was highly active after 6 days, nearly all of the reaction taking place in the first 1/2 inch of catalyst bed.
EXAMPLE 3
Sulfur Deactivation
At the end of the 6-day run of Example 2, the feed gas was modified by adding thereto 4 ppmv of H 2 S. After 17 hours, the respective temperatures were as follows:
TABLE 2______________________________________ Temperatures 17 Hrs After Introduction of 4 ppm H.sub.2 S, ° F ΔT From Feed Inlet or Feed Inlet From Preceding Thermo- 900° F couple, ° FThermocouple Cat A Cat B Cat A Cat B______________________________________1 900 900 zero zero2 " " " "3 " " " "4 " " " "5 " " " "6 " 915 " 157 905 945 5 30______________________________________
It is evident from the foregoing that substantially the entire portion of the catalyst bed in which the thermocouples were embedded had become deactivated.
EXAMPLE 4
Catalyst Reactivation
Following the sulfur deactivation of Example 3, each catalyst was reduced in a stream of hydrogen at 6660 GHSV for about 17 hours at 900° F, and 85-89 hours at 1100° F. Following this, methanation was resumed under the conditions of Example 2, with the following results:
TABLE 3______________________________________ Temperatures Immediately After Regeneration, ° F ΔT From Feed Inlet or Feed Inlet From Preceding Thermo- 900° F couple, ° FThermocouple Cat A Cat B Cat A Cat B______________________________________1 1085 1060 185 1602 1115 1115 30 553 1130 1125 15 104 1130 1130 0 55 1115 1115 -15 -156 1100 1100 -15 -157 1085 1085 -15 -15______________________________________
From the foregoing, it is evident that the initial activity of each of the regenerated catalysts was quite similar, approaching that of the respective fresh catalysts.
EXAMPLE 5
Regenerated Catalyst Stability
Methanation in the absence of H 2 S was continued as in Example 4 for an additional 6 days. At the end of the 6-day period the temperatures were as follows:
TABLE 4______________________________________ Temperatures 6 Days After Regeneration, ° F ΔT From Feed Inlet or Feed Inlet From Preceding Thermo- 900° F couple, ° FThermocouple Cat A Cat B Cat A Cat B______________________________________1 1000 915 100 152 1085 975 85 603 1115 1062 30 874 1137 1135 22 735 1125 1145 -12 106 1110 1135 -15 -107 1090 1120 -20 -15______________________________________
From the foregoing temperatures at thermocouple 1, it is evident that the top portion of catalyst bed B was almost completely deactivated after 6 days, while the corresponding portion of catalyst bed A still retained about 54% of the freshly regenerated activity shown in Table 3. At 46% deactivation per 6-day period, another 18 days, or a total of 24 days, would be required for catalyst A to reach the same state of deactivation which catalyst B reached in 6 days. It is thus evident that regenerated catalyst A is at least four times as stable as regenerated catalyst B.
The foregoing is however a conservative estimate because thermal deactivation of catalysts is not a simple arithmetic progression unless all active sites in the catalyst have the same activity and stability, which is not the usual case. A more realistic estimate would rank regenerated catalyst A as being about six times as stable as regenerated catalyst B, since after 6 days the upper portion thereof was only about one-sixth as active as the corresponding portion of catalyst A, as reflected by the ΔT values at the first thermocouple. Also, during the 6-day post-regeneration run, thermocouple 1 of catalyst B registered 1000° F after only 1 day, whereas thermocouple 1 of catalyst A did not decline to that temperature until 6 days had elapsed.
EXAMPLE 6
Sulfur Loss During Regeneration
Two samples of a catalyst essentially identical to catalyst A of the foregoing examples, which catalyst had been deactivated by sulfur deposition during methanation, were analyzed for sulfur content. One sample analyzed 0.22 weight-percent and the other 0.23 weight-percent of total sulfur. These low sulfur contents clearly reflect the fact that only a very minor portion of the total nickel content had been sulfided; yet the catalyst was almost completely inactive, having a very low specific surface area of Ni.
An 85 ml sample of the deactivated catalyst, in the form of 8-10 mesh particles was loaded into an elongated reactor and hydrogen, flowing at the rate of 20 SCF/hr., was passed through the catalyst bed at 900° F for 22 hours. The temperature was then raised to 1100° F over a period of 2 hours, and the flow of hydrogen was continued at 1100° F for an additional 82 hours. This regeneration treatment is essentially identical to that utilized in Example 4.
Following the reduction treatment, two samples of the catalyst were analyzed for sulfur content. The first sample was taken from the top 10% of the catalyst bed, while the second sample was a homogeneous composite taken from the lower (downstream) 90% of the bed. Both samples analyzed 0.19 wt.% total sulfur. The fact that, after 106 hours of hydrogen stripping, the upstream and downstream portions of the catalyst bed had identical sulfur contents clearly demonstrates that no sulfur was being removed at 106 hours, and also that the small amount of sulfur which had been removed must have been a different, labile form than the sulfur remaining. Despite the insignificant sulfur removal, the catalyst displays stable activity, as demonstrated in Example 5.
The following claims and their obvious equivalents are believed to define the true scope of the invention: | 4y
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a C-I-P application of application Ser. No. 08/210,708, filed Mar. 18, 1994, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to devices for burning solid wastes in rotary kilns and more particularly, to devices for injecting tires through the shell wall of rotary kilns.
The problem of disposal of scrap tires, typically from automotive use, is a growing one. At present, approximately 240 million scrap tires are generated each year in the United States and 25 million in Canada. The problem of tire disposal is compounded by the fact that may landfills are now refusing to accept whole scrap tires. Consequently, scrap tires must first be shredded or chipped in order to be accepted by landfills, which is a costly process and requires expensive chipping machinery.
An alternative is to burn the scrap tires whole. A preferred environment for burning scrap tires is a cement kiln, since material temperatures within the kiln typically reach 1594° C. (290020 F.)--sufficient to break down the constituents of the tires. A preferred zone of a rotary cement kiln for burning whole tires is the calcining zone where the material temperatures range from between 538.2° C. (1000° F.) to 1094.2° C. (2000° F.), or further down kiln at the beginning of the burning zone where temperatures are between 1094.2° C. (2000° F.) and the maximum expected temperatures of 1594° C. (2900° F.). A preferred zone of installation is where material temperature is above 760° C. (1400° F.) and less than 816.2° C. (1500° F.) and gas temperature comprised between 1205.4° C. (2200° F.) and 1594° C. (2900° F.). Temperatures too close to 1594° C. (2900° F.) could produce excessively rapid burning which would create a reducing atmosphere in the clinkering zone that could adversely affect the quality of the clinker produced by the kiln. Lower temperatures could result in slower ignition and burning incomplete combustion which can give off airborne pollutants.
Tire burning methods such as those disclosed in Tsuda U.S. Pat. No. 4,256,503, which include depositing whole tires in the precalcining zone or the cooling zone, both at the ends of the rotary kiln, are less desirable for this reason.
However, attempts have been made to charge a rotary kiln with whole tires directly through the shell wall in the calcining zone. An example of such a device is shown in Tutt, et al, U.S. Pat. No. 5,078,594. That patent discloses a device for charging whole tires into a cement kiln which includes a radially extending drop tube that projects inwardly from the shell wall, and an external closure which includes spring-loaded gates that open, when the device is at the 12 o'clock position, to allow a tire retained within the closure to travel through the drop chute onto the material within the cement kiln. A disadvantage with this type of design is the fact that the gate timing is fixed once the kiln is in operation and drop position and gate open time is not adjustable. Another limitation is the location of that device to feed into a cooler zone of the kiln, limiting heat release, complete combustion and tire substitution rate.
Accordingly, there is a need for an apparatus fully adjustable while the kiln is in operation as to the valve open position and duration, and which is able to withstand higher temperatures.
SUMMARY OF INVENTION
A construction in accordance with the present invention comprises an apparatus for feeding solid wastes into a cement kiln having an elongated tubular shell rotatable on its axis comprising a feed opening defined in the shell intermediate the ends of the tubular shell, a solid waste feeding assembly including a sleeve extending through the opening and forming a passageway having a radial axis with a first portion projecting into the interior of the kiln and a second portion exterior of the shell; the second portion of the sleeve including a substantially rectangular cross-section; a valve means in the second portion for closing and opening the passageway, the valve means including a gate pivotable about a first axis normal to the radial axis of the passageway and including a first planar wall extending in a plane including the pivot axis and a second wall joined to the first wall, the second wall being generated by a straight line parallel to the pivot axis whereby in a valve closed position the first wall closes off the passageway and the second wall extends across the passageway upstream of the first wall and in a valve open position the first and second walls are clear of the passageway.
In a more specific embodiment the second wall is perforated to allow circulation of ambient air between the first and second walls to cool the second wall.
In another aspect of the present invention, an apparatus for feeding solid wastes into a cement kiln having an elongated tubular shell rotatable on its axis comprising a feed opening defined in the shell intermediate the ends of the tubular shell, a solid waste feeding assembly including a sleeve extending through the opening and forming a passageway having a radial axis with a first portion projecting into the interior of the kiln and a second portion exterior of the shell; the first portion including a mound of refractory material formed within the interior of the kiln, the mound tapering to an apex spaced from the shell a distance greater than the height of the feedstock in the kiln when the mound is at the six o'clock position and a radial passageway is defined by the sleeve from the apex of the mound through to the second portion wherein the passageway has a cross-section sufficient to allow solid waste to be fed from the exterior of the shell into the kiln.
In a further aspect of the present invention an apparatus for feeding solid wastes for feeding solid wastes into a cement kiln having an elongated tubular shell rotatable on its axis comprising a feed opening defined in the shell intermediate the ends of the tubular shell, a solid waste feeding assembly including a sleeve extending through the opening and forming a passageway having a radial axis with a first portion projecting into the interior of the kiln and a second portion exterior of the shell; a delivery means to one side of the shell coincident with the general radial plane of the opening such that upon rotation of the kiln the second portion of the sleeve will be in an alignment position with the delivery means at one point in the rotational cycle of the kiln, that one point located in the quadrant between 3 o'clock and 12 o'clock in a counterclockwise rotation cycle of the kiln, the delivery means including a delivery tray and means for advancing the solid waste to the delivery tray, the delivery tray including a plurality of counterbalanced pivoting fingers with each finger balanced to be parallel and spaced to an adjacent finger and set at a slope angle sufficient to deliver the solid waste by gravity; stop means at the end of the fingers, the feed assembly on the shell of the kiln including a pick up means in the form of a fork wherein the fork includes elongated elements adapted to be interdigitated with the fingers of the delivery means when the pick up means passes the one point in the rotational cycle.
The present invention is an apparatus for feeding solid wastes such as tires through the shell wall of a rotary. kiln, preferably a cement kiln, so that the tires are dropped on the kiln load and are burned to provide a source of heat where heat is most needed. Preferably, the injection occurs at the end of the calcining zone, where gas temperatures range from about 1205 C.-1316.6° C. Consequently, the amount of convention fossil fuel needed for heating the cement raw feed is reduced and the environment benefits because used tires are eliminated.
The feed apparatus of the present invention is positioned relative to the kiln to feed tires to the interior of the kiln at a point at which the temperature is sufficient to minimize the amount of pollutants generated by the combustion of the tires. The mechanism of the present invention operates to feed tires continually to the interior of the kiln without significant loss of heat or material from within the kiln. While the preferred embodiment is designed particularly for the feeding of whole automotive tires, portions of large truck tires, light aircraft tires and the like into a kiln, other combustible material either containerized or in the form of relatively large pieces or bales, may be fed to the kiln by the apparatus of the present invention.
The present invention includes a frustopyramidal sleeve made entirely of refractory material and anchored to the inner kiln shell. In one embodiment the sleeve has a smooth outer surface and has an elliptical cross-section. A sleeve of this design resists heat better than sleeves having steel liners. The sleeve extends radially inwardly from the shell, having a height, when at the 6 o'clock position within the kiln, such that the radially inner end of the sleeve protrudes above the material in the kiln and prevents the kiln load to be at any time in contact with the opening gate. The sleeve is substantially self-supporting and includes a central, radially-extending elliptical passageway shaped to receive tires therethrough. The passageway inside the kiln is provided by a refractory cast injector sleeve which resists high temperature and abrasion from the material within the kiln.
The passageway includes a motorized sector valve or gate valve, mounted on the exterior of the kiln shell, which is actuated to close the passageway during normal operation and open as needed to admit a tire or tires to the kiln interior by gravity feed. The sector valve is vented for cooling purposes and is pivotally mounted within a metal housing attached to the exterior of the kiln shell. The sector valve includes two walls, one to seal the passageway and the other, which is vented to prevent overheating tires in contact with it, supports the tire to be fed and when it pivots open provides a sliding surface for tires entering the passageway when the first assembly is pivoted to open the passageway. A motor is provided to actuate the sector valve to open and close the material passageway rapidly. The motor action is directed by an exterior controller and the sector valve at other times is held in a predetermined position by a brake.
The preferred embodiment also includes a feeding component having a feed table which may be hand-loaded or automated to feed tires singly or in multiples as required by the kiln operator. The feeding component preferably includes a stationary presenting tray made of spaced rods shaped to hold a tire or tires to be fed, and the kiln-mounted housing includes a pickup tray made of spaced forks, aligned with the passageway. As the kiln rotates, the rods of the pickup tray pass upwardly between the rods of the presenting tray. Tires placed on the presenting tray are removed therefrom by the take-away tray and slide from the take-away tray through the open passageway and into the kiln interior by gravity as the kiln rotates the passageway before the take away tray passes through the 12 o'clock position.
In the automated embodiment of the present invention, the apparatus includes powered feed conveyors which deposit tires on the presenting tray. The conveyors preferably include automatic counting and weighing devices as well as all required sorting, orienting discarding, feed and storage devices to present tires as desired by the kiln operation.
Accordingly, it is an object of the present invention to provide an apparatus for the continuous feeding of one or more whole tires at a time into a rotary kiln through the kiln wall, thereby reducing the need to dispose of used tires in landfills and in other environmentally undesirable methods; an apparatus for burning whole tires in a cement kiln which reduces the amount of fossil fuel burned in the kiln to manufacture Portland cement; an apparatus having a radially-oriented internal sleeve made of refractory and of sufficiently low profile that it does not project substantially above the level of the material being processed within the kiln and yet does not allow material being treated to flow out of the kiln through the sleeve passageway; an apparatus in which the housing external to the kiln incorporates a motor-powered sector gate or valve to limit passage of gas or material in or out of the kiln and which is capable of rapid opening to admit tires by gravity to the kiln interior; an apparatus in which tires can be hand fed to the kiln or which can be fully automated so that personnel are not required to operate the apparatus adjacent to the kiln shell; and an apparatus which can be operated continuously with the kiln, is capable of receiving whole tires without preprocessing and is relatively easy to operate and maintain.
Other objects and advantages will be apparent from the following description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary radial cross-section, of a cement kiln incorporating an embodiment of the present invention;
FIG. 2 is a detail of the interior kiln of FIG. 1 showing the sleeve partially broken away;
FIG. 3 is an enlarged schematic radial cross section of the embodiment shown in FIG. 1;
FIG. 4 is a fragmentary axial cross-section taken along lines 4--4 of FIG. 3;
FIG. 5 is a detail of the mechanism of FIG. 1 showing the sector valve;
FIG. 6 is a fragmentary perspective view of a further detail of the present invention;
FIG. 7 is a fragmentary perspective view showing a detail of an embodiment of the present invention;
FIG. 8 is a schematic top plan view showing the engagement of the presentation and pickup trays of the embodiment of FIG. 7; and
FIGS. 9, 10 and 11 are schematic views, in section, of the mechanism of FIG. 7, showing the mechanism as the kiln rotates through a tire pickup and feed cycle.
DETAILED DESCRIPTION
As shown in FIG. 1, the apparatus for feeding whole tires into a rotary kiln is generally designated 10 and is designed to be incorporated into a rotary kiln 12 having a shell 14 of good quality steel and an inner refractory liner 16. The shell 14 may be reinforced in order to carry the feed assembly 10. The kiln preferably is of the long variety and may not include a preheater. The feed assembly 10 preferably is positioned to feed tires 81 into the end of the calcining zone, where temperature range is from between about 2200° F. and 2400° F. (1204° C. and 1316° C.). Within the kiln 10 is a bed 18 of material which is heated and transformed into cement klinker by well-known means.
The kiln wall feed assembly 10 includes an aperture 19 in the shell 14 and sleeve 20, within the kiln coincident with the aperture 19, generally frustopyramidal and has an elliptical cross-section. The sleeve 20 is attached to the shell 14 by a plurality of anchors 23 which consist of stainless steel rods. The sleeve 20 is made of reinforced refractory material and includes an elliptical passageway 21 and a radially inner flat surface 22. The sleeve 20 is sized to protrude above the bed 18 of material when rotated to the 6o'clock position. The sleeve 20 has sloped smooth walls 20A with a somewhat elliptical cross-section in the axial direction wherein the major axis of the ellipse is parallel to the longitudinal axis of the kiln 12. This design permits the material 18 to flow past the sleeve 20 with a minimum of obstruction. Furthermore, the formation of the sleeve 20 constructed mostly of refractory material allows the location of the sleeve 20 in areas of the kiln which are too hot for a conventional drop tube of the prior art. Thus, the sleeve 20 may be located slightly upstream of the calcining zone (in relation to the direction of the gases). It is believed that the ideal location for feeding tires into the kiln is in the hotter zone on the edge of the calcining zone rather than in the cooler calcining zone.
A housing, generally designated 24, is mounted on the exterior of the shell 14 and includes a sector valve assembly 26. Sector valve assembly 26 includes a stub sleeve 28 which extends within the sleeve 20 through an opening 30 in the shell 14.
A gate member 32 is mounted on the housing 24 and includes primary and secondary walls 34, 36. As shown in FIGS. 1, 3 and 5, primary wall 34 is arcuate in shape and secondary wall 36 is planar in shape. Primary and secondary walls 34, 36 are joined along lateral edge by wedge-shaped side walls 38. Secondary wall 36 is perforated to allow for air flow of ambient air through the area between primary and secondary walls 34, 36 for purposes of cooling primary wall 34 and secondary wall 36. The gate 32 when closed, prevents air from entering the sleeve 28 and thus the kiln 12.
Gate member 32 is mounted on a shaft 42 which, in turn, is mounted on a frame of housing 24 and is rotated by rotary motor 44. The bottom end of gate 32 is open. Gaps may be provided, such as gap 46 between the wall 48 of stub sleeve 28 and the primary wall 34, in order to allow some ambient air to enter the sleeve 28 along the wall 34 to reduce the temperature of the wall 34.
A secondary gate 56, shown in FIG. 3, is substantially L-shaped and is mounted for pivoting on axle 58 which in turn, is mounted on housing 24. Motor 60 pivots axle 58 so that door 56 is alternatively moved from the position shown in solid line in FIG. 1 (an opening configuration) to the position shown in phantom and designated 62 (a closed configuration) in which the stub sleeve 28 opening is closed upstream of the gate member 32. This secondary gate 56 is an emergency gate and would be used in the event that gate 32 becomes jammed or otherwise inoperable.
The housing 24 is supported in a generally radial configuration by struts 68. Heat shields 70 are also supported on the housing 24 to protect electronic components and motors from heat damage from the kiln 12.
Also as shown in FIGS. 1 and 7, the apparatus 10 includes a tire feeding mechanism generally designated 72 which includes an accumulator conveyor 74 (FIG. 1), presentation tray 76 and takeup tray 78. The accumulator conveyor 74 includes a plurality of rollers 79, which in the preferred embodiment are driven rollers. Alternatively, the accumulator conveyor includes a reciprocating hydraulic cylinder motor 80 which is capable of pushing tires 81 which have accumulated on the rollers 76 forwardly from the accumulator conveyor 176. A sensor/controller detects the presence of tires on the conveyor 74 and activates the cylinder 80 to feed tires uniformly to tray 76 for a pick up. Guide bars 77 prevent the tires from tumbling down the tray 76.
The presentation tray 76 includes a plurality of spaced bars 83 which support the tires 81. The bars 83 are inclined to the horizontal sufficiently to allow the tires 81 to slide downwardly by gravity. The tires 81 are held on the presentation tray 76 by end fingers 84 which project upwardly from the ends of the tubes 82.
The bars 83 are pivoted about a shaft 82 and are balanced by counterweight 83A. Side panels 76A are located on the other bars 83. Thus, all of the bars 83 of the presentation tray 76 are counter levered and can pivot about the shaft 82 if these bars are struck by an object such as the presentation tray 76 in the event the forks 86 of the presentation tray 76 were misaligned.
Considerable damage can be avoided by this construction. The bars 83 are balanced at the proper angle to present the tires 81 by fine-tuning the counterweights 83A.
Guide bars 77 extend over the presentation tray 76 and serve to prevent the tires from tumbling as they are fed on the slope formed by the bars 83.
The takeup tray 78 includes a plurality of spaced forks 86 which are positioned to mesh with or pass between the spaced fingers 83 of the presentation tray 76 as the kiln 12 rotates counter clockwise. The forks 86 are mounted to the stub sleeve 28. Side panels 88 are provided to guide the tires into the sleeve 28.
As shown in FIG. 1, rings 90 (only one of which is shown) encircle the shell 14. Thermocouple 92 is mounted on the shell 14 and includes a sensor 94 which extends within the sleeve 20. Thermocouple 92 is connected to one of the slip rings 90 so that a signal is received by pick up 96 and conveyed to appropriate instrumentation 98 for recording and display. Electrical power is provided by control source 100 and is transmitted to another set of rings 90 by pick up 102. Electrical devices such as motor 44 include pick ups 104 which are connected to the slip rings 90 and transmit electrical power through conduits 106 to motor 44. This connection allows the timing of opening and closing of the gate 32 to be varied by remote control.
As shown in FIGS. 9 to 11 the procedure for feeding tires 81 into the kiln 12 is shown sequentially. In FIG. 9, the housing 24 is rotated counterclockwise by the kiln 12 so that the pick up tray 78 approaches the presentation tray 76, which has been loaded with tires 81 from accumulator conveyor 74. At this time, the gate member 32 is pivoted to the closed configuration shown.
As the pick up tray 78 passes upwardly through the presentation tray 76, as shown also in FIG. 8, the tires 81 are transferred from the presentation tray 76 to the pick up tray 78. As the housing 24 continues to rotate upwardly, the force of gravity causes the tires 81 to begin sliding along the pick up forks 86 and toward stub sleeve 28. The motor 44 is actuated by a control 100, to pivot the gate member 32 to an open configuration, at which time the secondary wall 36 is aligned such that is co-planar with the bottom wall of the stub sleeve 28 (see FIG. 11).
As shown in FIG. 11, with the gate member 32 in this position, the tires 81 are free to slide radially into the interior of the kiln 12 through the stub sleeve 28 and passageway 21 of the refractory sleeve 20. Once the housing 24 has swept past a preselected position (between 11 and 12 o'clock), the motor 44 is actuated by control 100 to pivot the gate member 32 to the closed configuration shown in FIG. 9. The gate member 32 remains in the closed position throughout the remainder of the rotation of the kiln 12, until once again it sweeps through and past the presentation tray 76.
The sleeve 20 preferably is sized such that, when the sleeve is at the 6 o'clock position, the radially inner end 22 protrudes above the material in the bed 18 of the kiln (approximately 4 feet or 1.2 meters). This minimizes the amount of material that may fall through the sleeve opening and contact the stub sleeve 28 and gate member 32. While the preferred embodiment shows a sleeve 20 which is substantially radial in orientation, it is within the scope of the invention to provide tangentially-angled sleeves.
While the forms of apparatus herein described constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to these precise forms of apparatus and that changes may be made therein without departing from the scope of the invention. | 4y
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PRIORITY CLAIM
[0001] This application claims the benefit of priority of U.S. Provisional Patent Application No. 61/706,923, filed Sep. 28, 2012, which is incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
[0002] The subject matter of the present disclosure relates generally to a tire having ribs that fully or partially extend diagonally across the transverse direction of the tread region and have a plurality of sipes defined in the trailing edge of the ribs.
BACKGROUND OF THE INVENTION
[0003] Tires having continuous ribs oriented parallel to the longitudinal direction of the tread are commonly used on e.g., commercial vehicles. A common placement of such designs on commercial vehicles can include the steer tire positions on a commercial truck. Ribs constructed in such a manner can provide rolling resistance performance that is much better than e.g., tread patterns having blocks or non-continuous ribs. Improved rolling resistance performance can provide better fuel efficiency, a particularly desirable feature in view of increasing fuel costs.
[0004] One challenge with ribs oriented parallel to the longitudinal direction, however, is relatively poor traction performance. This characteristic results from e.g., the lack of transverse edges that provide grip as the tire rolls over the road surface. Thus, tires having such rib construction are typically not used on e.g., the drive tires of commercial vehicles. Instead, as stated above, such tires are commonly placed in the steer positions where a high level of longitudinal traction is not required.
[0005] Additionally, such longitudinally oriented ribs are subject to irregular wear. As used herein, “irregular wear” means that the wearing of the ribs is not uniform from rib to rib. Such irregular wear can e.g., shorten the life of the tread and create unwanted vibrations as the tire rolls across the road surface. Although siping can be added to reduce such irregular wear, such can also adversely affect rolling resistance performance.
[0006] Accordingly, a ribbed tire that provides desired rolling resistance and traction performance would be useful. More particularly, a tire that can provide the rolling resistance performance of a continuous rib while also providing needed traction performance would be beneficial. Such a tire that can also be provided with features for preventing or reducing irregular wear would also be very useful.
SUMMARY OF THE INVENTION
[0007] The present invention provides a tire having a tread region that includes continuous ribs that fully or partially extend diagonally across the transverse direction of the tire. Partial sipes are provided at the trailing edges of the ribs. Full sipes can also be provided along with the partial sipes. The ribs may form various patterns such as e.g., an S-shaped pattern, chevron pattern, and others. The tire provides improved traction performance over non-diagonal ribs while still providing desirable rolling resistance performance and control of irregular wear. Additional objects and advantages of embodiments of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
[0008] In one exemplary embodiment, the present invention provides a tire defining longitudinal, radial, and transverse directions. The tire includes a pair of opposing shoulders spaced apart along the transverse direction. A tread region extends between the shoulders. The tread region includes a plurality of ribs separated by grooves and extending from one of the shoulders to the other of the shoulders. Each of the ribs has a rib length and a rib width. Along the rib length, each of the ribs forms a non-zero angle α from the longitudinal direction. Relative to the direction of tire rotation, each of the ribs includes a leading edge and a trailing edge—where the leading edge is the edge that rolls through the contact patch first. The trailing edge defines a plurality of partial sipes spaced apart along the length of the rib. The partial sipes have a sipe length SL that is less than the rib width. The leading edge does not have any partial sipes.
[0009] In another exemplary embodiment, the present invention provides a tire defining a centerline and defining longitudinal and transverse directions. The tire includes a pair of opposing shoulders spaced apart along the transverse direction. A tread region extends between the shoulders. The tread region includes a first plurality of ribs separated by grooves and extending from one of the shoulders to substantially the centerline of the tread region. A second plurality of ribs is also separated by grooves and extends from another of the shoulders to substantially the centerline of the tread region so as to approach the first plurality of ribs. Each of the first plurality and second plurality of ribs have a rib length and a rib width. The first plurality of ribs forms a non-zero, positive angle+α 1 from the longitudinal direction along their rib length. The second plurality of ribs forms a non-zero, negative angle −α 2 from the longitudinal direction along their rib length. Each of the first and second plurality of ribs includes a leading edge and a trailing edge. Each trailing edge defines a plurality of partial sipes spaced apart along the length of the rib. The partial sipes have a sipe length SL that is less than the rib width. The leading edge does not have any partial sipes.
[0010] In still another exemplary embodiment, the present invention provides a tire that defines longitudinal, radial, and transverse directions. The tire includes a pair of opposing shoulders spaced apart along the transverse direction. A tread region extends between the shoulders. The tread region has a rolling tread width RTW. The tread region includes a plurality of ribs separated by grooves and extending along the tread region. Each of the ribs having a rib length RL and a rib width RW. Along the rib length RL each of the ribs forms a non-zero angle α from the longitudinal direction and the value of RL*cos(α) is about 40 percent of the rolling tread width RTW or greater. Each of the ribs includes a leading edge and a trailing edge. The trailing edge defines a plurality of partial sipes spaced apart along the length of the rib. The partial sipes have a sipe length SL that is less than the rib width RW. The leading edge does not have any partial sipes.
[0011] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0013] FIG. 1 illustrates a perspective view of an exemplary embodiment of a tire of the present invention.
[0014] FIG. 2 is a close up, perspective view of a portion of the tread region of the exemplary embodiment of FIG. 1 .
[0015] FIG. 3 is a cross-sectional view of a portion of the tread region of the exemplary embodiment of FIG. 1 .
[0016] FIG. 4 is a close-up, perspective view of a portion of an exemplary embodiment of a tread of the present invention with hidden features shown in dashed lines.
[0017] FIGS. 5 , 6 , 7 , and 8 are perspective views of additional exemplary embodiments of the present invention.
[0018] FIG. 9 is a close up, perspective view of a portion of the tread region of another exemplary embodiment of the present invention.
[0019] FIGS. 10-12 are graphs of certain data as will be further described below.
[0020] FIG. 13 is a close up, perspective view of a portion of the tread region of another exemplary embodiment of the present invention.
[0021] The use of the same or similar reference numerals in the figures denotes same or similar features.
DETAILED DESCRIPTION
[0022] For purposes of describing the invention, reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0023] FIG. 1 illustrates an exemplary embodiment of a tire 100 constructed according to the present invention. Tire 100 defines a transverse direction T that is parallel to the axis of rotation A. A radial direction R extends from the axis of rotation A and is perpendicular thereto. Tire 100 also defines a longitudinal direction L ( FIGS. 6 and 7 ) that is perpendicular to both the transverse direction T and radial direction R at any point along the tread region 102 of tire 100 . Longitudinal direction L is also tangent to a circumferential direction C of tire 100 at any point along tread region 102 .
[0024] Tire 100 includes a pair of opposing shoulders 104 and 110 spaced apart from each other along transverse direction T. Tread region 102 extends between shoulders 104 and 110 along transverse direction T and also extends circumferentially around tire 100 . Tread region may include e.g., notches 146 of other features along each shoulder of tire 100 . Tire 100 also includes a pair of sidewalls 112 and 114 on opposing sides of tire 100 .
[0025] Tread region 102 includes a plurality of ribs 106 separated by grooves 108 . Each of the ribs 106 has a rib length RL and a rib width RW. Ribs 106 each extend diagonally from one shoulder 104 to the other shoulder 110 . Although shown for this embodiment as uninterrupted across the entire rib length RL, the present invention includes exemplary embodiments where one or more ribs may be interrupted along their rib length RL by grooves or other features.
[0026] As shown in FIGS. 1 and 2 , each rib 106 has a rib length RL that forms a non-zero angle α (45 degrees in FIGS. 1 and 20 degrees in FIG. 5 ) from the longitudinal direction L. For example, in certain exemplary embodiments, the absolute value of angle α is in the range of about 10 degrees to about 60 degrees. In still other embodiments, the absolute value of angle α is about 20 degrees or about 60 degrees. It should be noted that in FIG. 1 as viewed by the reader, ribs 106 extend diagonally upward from left to right and provide for a positive angle α from the longitudinal direction L, which can be denoted as +α as shown in FIG. 1 . However, in other embodiments, ribs 106 extend downwardly from left to right and still form a non-zero angle α from the longitudinal direction L. In such instance, angle α will provide for a negative angle α, which can be denoted as −α as shown in FIG. 2 . Regardless of which directions for ribs 106 are used, the absolute value of angle α is in the range of about 10 degrees to about 60 degrees for these exemplary embodiments as previously stated.
[0027] Continuing now with FIGS. 1 , 2 , and 3 ribs 106 each have a leading edge 116 and a trailing edge 118 as defined by rolling direction RD, where the leading edge 116 is the first edge to enter the contact patch as the tire rolls and the vehicle moves in a forward direction. More particularly, the configuration of ribs 106 provides tire 100 with a directional tread pattern. As such, when a vehicle equipped with tire 100 is moving in a forward direction, leading edge 116 of a rib 106 contacts the road surface before trailing edge 118 as tire 100 moves along rolling direction RD and each rib 106 moves through the contact patch.
[0028] Trailing edge 118 of each rib 106 defines a plurality of partial sipes 120 that are spaced apart along rib length RL. Partial sipes 120 are “partial” meaning they each have sipe length SL shorter than rib width RW such that they do not extend fully across rib width RW of rib 106 . Each partial sipe 120 is spaced apart along the direction of rib length RL from an adjacent partial sipe 120 by a spacing S. Each partial sipe 120 has a sipe depth SD. For this exemplary embodiment, spacing distance S is less than about 1.5 times sipe depth SD. In turn, sipe depth SD is at least about 50 percent of the height H of ribs 106 along the radial direction R. ( FIG. 3 ). Partial sipes 120 also have a sipe length SL that is at least about 50 percent of the spacing S between partial sipes 120 .
[0029] Referring specifically to FIG. 2 , partial sipes 120 each form an acute angle β from the transverse direction T. Angle β has an absolute value in the range of about zero degrees to about 45 degrees. It should be noted that in FIG. 2 as viewed by the reader, ribs 106 extend diagonally upward from left to right such that angle β has a positive value denoted +β. However, in other embodiments, ribs 106 extend downwardly from left to right and will still form an acute angle −β from the transverse direction T having an absolute value in the range of about zero degrees to about 45 degrees.
[0030] Along sipe depth SD, partial sipes 120 can be straight as shown in FIG. 3 . Alternatively, various features may be added to assist with durability, wear rate, and irregular wear in other embodiments of the invention. For example, as shown in FIG. 4 , sipes 120 could include one or more waves or undulations 122 along radial direction R. Other types of shear locking features may be used as well. Undulations or other shear locking features may also be provided along sipe length SL.
[0031] A variety of shapes and/or orientations may be used with the diagonal ribs 106 that will provide tire 100 with different appearances. In FIG. 1 , the diagonal ribs 106 of tire 100 are relatively straight along rib length RL. FIG. 5 provides another exemplary embodiment of tire 100 in which ribs 106 are provided at a different angle α from the longitudinal direction L. Other configurations may also be used. For example, ribs 106 may be provided with a slight curvature so to create an overall corkscrew or S-shape for each rib 106 .
[0032] FIGS. 6 , 7 , and 8 each show additional exemplary embodiments of tire 100 where diagonal ribs are arranged to create chevron patterns. More particularly, for each embodiment, tire 100 includes a first plurality of ribs 124 separated by grooves 126 and extending from shoulder 104 to substantially the centerline C/L of tread region 102 . Tire 100 also includes a plurality of ribs 128 separated by grooves 130 and extending from the other shoulder 110 to substantially the centerline C/L of tread region 102 so as to meet ribs 124 . For the embodiments of tire 100 shown in FIGS. 6 and 7 , grooves 126 and 130 meet at centerline C/L whereas in FIG. 8 grooves 126 and 130 are offset from each other at centerline C/L. In still other embodiments of the invention, grooves 126 and 130 may approach each other without necessarily touching and/or without meeting only at the centerline C/L.
[0033] First plurality of ribs 124 each have a rib length RL and a rib width RW. Along their rib length RL, ribs 124 are positioned at a non-zero, positive angle +α 1 from the longitudinal direction L. Second plurality of ribs 128 each have a rib length RL and a rib width RW. Along their rib length RL, second plurality of ribs 128 are positioned at a non-zero, negative angle −α 2 from the longitudinal direction L. For each exemplary embodiment shown, the absolute value of angle α x for ribs 124 and 128 is identical. However, in other exemplary embodiments of the invention, the absolute values of α 1 and α 2 may be different or non-equal. Comparing FIGS. 6 and 7 , the absolute value used for angle α is greater in FIG. 7 . Other values may be used to provide a different appearance. As with the exemplary embodiment of FIG. 1 , the absolute value of angle α is in the range of about 10 degrees to about 60 degrees.
[0034] In a manner also similar to the exemplary embodiment of FIG. 1 , ribs 124 each have a leading edge 132 and a trailing edge 134 . A plurality of partial sipes 136 are defined by trailing edge 134 in a manner similar to partial sipes 120 . Ribs 128 each have a leading edge 138 and a trailing edge 140 . A plurality of partial sipes 142 are defined by trailing edge 140 in a manner similar to partial sipes 120 but with an opposite orientation. For each of the embodiments of FIGS. 6 , 7 , and 8 , partial sipes 136 and 142 have a spacing S, a sipe depth SD, and a sipe width SW as previously described with regard to the embodiment of FIG. 1 . Similarly, partial sipes 136 and 142 form an acute angle β (+β or −β) from the transverse direction, wherein angle β has an absolute value in the range of about 0 to about 45 degrees.
[0035] Chevron patterns other than what is shown in e.g., FIGS. 6 , 7 , and 8 may be used as well for the ribs of tire 100 . For example, the chevron pattern may be oriented 90 degrees from what is shown in these figures. U.S. Design Pat. No. 352,486 provides an example of such an orientation.
[0036] The above description has provided examples of tire 100 with partial sipes—i.e. sipes extending from the trailing edge and partially across the width of a respective rib. However, the present invention includes full width sipes as well. For example, FIG. 9 provides a view similar to the embodiment of FIG. 2 except partial sipes 120 alternate with full width sipes 121 . For sipes 121 , aspects such as the sipe depth SD, angle β, and undulations can be provided in a manner similar to that previously described with regard to the embodiment of FIGS. 1 and 2 . Patterns other than alternating between full width sipes 121 and partial sipes 120 may also be used. For example, FIG. 13 provides another exemplary embodiment for the tread of tire 100 in which multiple, partial sipes 120 are positioned between full width sipes 121 as shown.
[0037] The rib length RL for the exemplary embodiment of FIGS. 1 and 5 is such that ribs 106 extend substantially or completely across the rolling tread width RTW of tread region 102 . In FIGS. 6 , 7 , and 8 , rib length RL of ribs 124 or 128 extends only partially across the rolling tread width RTW such that rib length RL is less than that of the exemplary embodiments of FIGS. 1 and 5 . As used herein, rolling tread width RTW is the width of the tread—as measured along transverse direction T—that is in contact with the ground surface as the tire moves through the contact patch. For all exemplary embodiments of the invention described above, the product of the rib length RL and the cosine of angle α is equal to, or greater than, about 40 percent of the rolling tread width RTW. This can also be expressed as RL*cos(α) is the same, or greater than, about 40 percent of the rolling tread width RTW.
[0038] Rolling resistance measurements were conducted for five different tires A through E constructed according to various exemplary embodiments of the invention as identified in TABLE I below. Rolling resistance was measured on a drum at maximum nominal loads and pressures at about 90 kilometers per hour. All tires had a tread having the same void volume ratio. The notches referenced in Table I are notches such as notches 146 shown in FIG. 1 and located on the exterior shoulders of tire 100 . For tires A through D, each tire was tested without notches or partial sipes, with notches but not partial sipes, and with notches and partial sipes. RR as referenced in Table I refers to rolling resistance coefficients expressed in values of Kg/T (kilograms of resistance force/ton of load).
[0000]
TABLE 1
Tire A
Tire B
Tire C
Tire D
Tire E
Rib description
α = 20°/
α = 45°/
/α/ = 25°/
/α/ = 45°/
7 straight ribs
CorkScrew
CorkScrew
Chevron
Chevron
RR with no
3.62
3.41
3.62
3.54
3.67
notches or sipes
RR with notches
3.72
3.5
3.81
3.72
but no sipes
RR with notches
3.68
3.55
3.85
3.72
and 20 mm sipes
[0039] As shown, for tires A through D, an unexpected result occurs in that the addition of partial sipes did not increase rolling resistance RR.
[0040] FIGS. 10 , 11 and 12 provide graphs of for contact force measurements taken along the trailing edge of a rib of an exemplary embodiment of a tire of the present invention while the tire was submitted to a driving torque. Each figure includes an inset I depicting the location of sensor S. FIG. 10 represents a plot for a tire having ribs 148 without siping. FIGS. 11 and 12 represent plots for a tire having ribs 148 with partial sipes 150 with a sensor S positioned on different sides of partial sipe 150 as shown. In these figures, Fx represents a force along longitudinal direction L, Fy represents a force along the transverse direction T, and Fz represents a force normal to the road surface. As shown in FIGS. 10 , 11 , and 12 , the addition of partial sipe 150 leads to a reduction of contact force and stress in the kickout area—particularly in the area behind the sipe as shown in FIG. 11 .
[0041] By using the ratio of tangential force divided by the normal force (Ft/Fz), a sliding potential can be represented by the duration this Ft/Fz ratio exceeds some given threshold. This threshold would be akin to the coefficient of friction and would depend on many factors such as the type of ground, tread compound, temperature, sliding speed, etc. For purposes of further describing the invention, a threshold of 0.8 was selected for analysis. Multiplying this sliding potential by the Fz force gives a value that would be roughly proportional to the frictional dissipated energy and can be viewed as a form of a wear indicator. Accordingly, the product of the sliding length potential multiplied by force Fz measured for an exemplary embodiment of a tire having an angle α of twenty degrees for its diagonal ribs was determined.
[0042] Unexpectedly, the results indicated a benefit for partial sipes on the trailing edge for a driving torque condition. The lead edge of the rib showed a significant amount of wear potential under driving, free rolling, and braking conditions, but such was merely an edge effect that goes away in the first miles of wear and then stabilizes. Under the free rolling and braking conditions, no benefit was seen with the trailing edge sipes, which makes the design of the present invention more beneficial for the drive axle positions. However, importantly the trailing edge sipes showed no detrimental effects under these conditions, particularly under the braking conditions. This is a very good result because braking conditions are typically when abnormal wear can be initiated and propagated.
[0043] Finite element analysis (FEA) was also used to predict the wear of trailing edge sipes through modeling of a single rib having a rib width RW of 50 mm. As with above, frictional sliding was used as a wear indicator but was calculated from the FEA by the dot product of the displacement vector (sliding) and tangential force vector for each time step and summed for each node.
[0044] The FEA revealed that under driving torque, ribs with only partial sipes or ribs with both partial and full sipes will reduce the wear prediction at the trailing edge. Sipes having a sipe length SL of 20 mm reduced the wear only at the trailing edge whereas the full width sipes showed a tendency to reduce wear of the overall rib. Smaller sipe spacings S of 15 mm concentrated the wear reduction even more along the trailing edge and had a more uniform wear along the leading edge.
[0045] FEA analysis also revealed that full width sipes can be used to improve the overall wear rate while trailing edge sipes can be used to target wear rate reduction at the trailing edge. Ribs which combine both full and partial width sipes can be used to accomplish both of these effects. Accordingly, FEA was used to analyze a diagonal rib (with a of 20 degrees) having full width siping and ribs having both full and partial siping with sipe lengths SL and spacing S as indicated in Table II below.
[0000]
TABLE II
SW = combinations
SW = combination
Solid
SW = 20 mm,
SW = full,
SW = 20 mm,
of full width and
of full width and
rib
S = 30 mm
S = 30 mm
S = 15 mm
10 mm, S = 15 mm
7.5 mm, S = 15 mm
Driving
100
86
66
81
68
70
Braking
91
85
85
95
88
93
50/50
97
87
77
90
79
83
braking/driving
10/90
99
87
68
83
70
72
braking/driving
[0046] The values shown are percents relative to the solid rib having a width of 50 mm under driving torque conditions. A lower number represents a slower (i.e. better) wear rate. As shown, the full width siping without partial width siping provided the best overall wear performance for both driving and breaking A wear penalty appears when partial width siping is added to the trailing edge, but this penalty decreases as the use of the tire becomes dominated by a driving torque—indicating such design is best suited for drive axle applications. Even though full width siping alone appears to provide an improvement in wear life, it will negatively affect rolling resistance. However, the addition of partial sipes on the trailing edge provides an improvement to wear and irregular wear without negatively impacting rolling resistance.
[0047] While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art using the teachings disclosed herein. | 4y
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This is a continuation of application Ser. No. 07/655,575, Dec. 24, 1990, abandoned, which is a continuation-in-part application of patent application Ser. No. 07/306,699, filed Dec. 24, 1990, now U.S. Pat. No. 5,013,214 issued May 7, 1991. This invention relates to hydraulic turbine drives and especially to high velocity hydraulic turbine drives.
BACKGROUND OF THE INVENTION
High speed rotating apparatuses, such as high frequency electric generators are often driven by low frequency electric motors or internal combustion engines. In such cases a speed increasing gear box is needed. When the apparatus is driven by a high speed gas turbine, often a speed reducing gear box is needed. Portable grinding and cutting rotating tools are usually driven by high speed pneumatic or electric motors. Sometimes, such tools require a flow of liquid coolant to prevent overheating and also to prevent metal sparks form igniting adjacent materials. Consideration of weight and power output of such tools is very important to its portability.
SUMMARY OF THE INVENTION
The present invention provides a high speed hydraulic turbine drive. A nozzle body contains a number of nozzles through which hydraulic fluid is discharged to impinge on the blades of a turbine wheel which is fully submerged in the hydraulic fluid. The nozzles are cylindrical or part conical and part cylindrical and the center line of the nozzles for an angle of about 10 to 30 degrees with the outlet surface of the nozzle body. A manufacturing method is provided which permits the manufacture of drives of various power using the same standard machined parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional elevation in an axial plane of a turbine drive showing some of the features of the present invention.
FIG. 2 shows a turbine according to the present invention directly driving an electric generator.
FIG. 3 is a view of the nozzle body of the present invention.
FIG. 4 is a view showing the position of turbine blades relative to nozzle passages.
FIG. 5A is a sectional view along the line 5A--5A of FIG. 6A of nozzle passage for a relatively lower horsepower turbine.
FIG. 6A is a view of the nozle body for a relatively lower horsepower turbine.
FIG. 7A is a sectional view of the turbine wheel for a relatively lower horsepower turbine.
FIG. 5B is a sectional view along the line 5A--5A of FIG. 6A of nozzle passage for a relatively higher horsepower turbine.
FIG. 6B is a view of the nozle body for a relatively higher horsepower turbine.
FIG. 7B is a sectional view of the turbine wheel for a relatively higher horsepower turbine.
FIG. 8 shows a grinder attached to a water turbine drive.
FIG. 9 shows an electric generator being driven via a belt pully.
FIG. 10 shows an embodiment of the present invention as a garbage disposal unit.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention can be described by reference to the drawings. A preferred embodiment of a light weight water turbine drive is shown in FIG. 1. This turbine is extremely efficient at speeds in the range of 1800 RPM to 24,000 RPM and with loads in the range of 1/2 to about 50 horsepower. Essentially any corresponding high speed rotating load in this range can be attached directly to the shaft 18. For slower speed rotating loads gear or belt pulley reduction may be required. Turbine nozzle body 16 is firmly attached to bearing housing 76. Together they contain rolling element bearings 21. Said bearings provide for rotable radial and axial support to shaft 18 which at its rear end supports a firmly attached axial flow bladed water turbine wheel 26 incorporating blades 19. The front of the shaft could be attached to any one of a number of rotating loads. Since the turbine wheel in this embodiment is water driven, a convential sliding shaft seal 22 is provided sealing the water filled cavity 40 from air filled cavity 41 located on the opposite of seal 22. Water is supplied to the water turbine at a pressure ranging typically form 40 to 180 PSIG into the annular water turbine inlet cavity 30 through turbine inlet passage 35. The annular water turbine inlet cavity 30 supplies high pressure water to a plurality (twelve in this embodiment) of turbine nozzles configured as round holes with generally varying diameter and positioned appropriately within the nozzle's body 16, so as to produce maximum hydraulic effenciency in combination with the turbine wheel blades 19. Such turbine nozzles are identified as 50 in FIG. 1. As indicated in FIGS. 3 and 4, the turbine nozzles are drilled at an angle of about 10 to 30 degrees with the plane of the face of the nozzle body outlet surface. In my prototype designed for 2 to 6 horsepower at a 160 PSIG inlet pressure and a design speed of 10,000 RPM, the angle was 15 degrees. It is unlikely that the angle need be greater than about 30 degrees or less than 10 degrees. FIG. 3 shows the plane view of the exit portion of the turbine nozzles 50 as viewed in the plane 3--3 in FIG. 4. FIG. 4 shows a section through the nozzle body 16 along the plane 4--4 in FIG. 3 and combines such view with the plane view of turbine blades 19 and turbine wheel 26. The high pressure water is fed from annular water turbine inlet cavity 30 into the plurality of turbine nozzles 50. The water flow accelerates through nozzles 50 converting the pressure energy into kinetic energy with minimum hydraulic losses.
High hydrodynamic efficiency of nozzles 50 is attributed to the particiular combination of round cross sectioned nozzles 50 and the gradual change in the cross section of the flow area along the centerline axis of the individual nozzles 50. The turbine nozzles 50 are positioned close to each other within the nozzle body 16 so as to produce minimum wakes of low velocity fluid in between the passage areas of nozzles 50 and turbine blades 19. Such wakes are considered to be generally harmful to the turbine hydraulic efficiency. Such nozzle positioning as shown in FIGS. 3, 4, 5A, 6A, 5B, and 6B maximizes the percentage of the turbine blades frontal flow area occupied by the high velocity fluid relatively to the frontal flow area occupied by the wakes.
It should be noted here that many hydraulic fluids other than water could be used to power turbine drive units built according to this invention. Persons skilled in the art are aware of the minor changes that should be maintained to retain high effiencies taking into account the differing vicosities of the various hydraulic fluids which could be used.
ELECTRIC GENERATOR
A preferred embodiment of the present invention is to drive a high speed electric generator as shown in FIG. 2. The water turbine 80 is driving high frequecy electric generator 72. In this embodiment the turbine shaft is directly coupled via coupling 74 to generator 72. Excellent power matching between generator and turbine is being achieved. In this embodiment the diameters of turbine nozzle throats shown as 51 in FIG. 4 are increased by 20 percent and inlet pressure is 200 psi and operating speed of 12,000 RPM is specified to match commercially available Bendix electric generator Model 28B285-43 pr oducting up to 8 KVA at 400 Hz frequecy. As shown in FIG. 2, electric generator 72 is mounted on frame 71. Adapter housing 73 is attached concentrically to electric generator 72 and turbine 80. Mounting flange design on turbine 80 is modified in this embodiment to fit the specific configuration of adopter housing 73.
Another preferred embodiment of the present invention is shown in FIG. 8. In this embodiment a rotating grinding wheel 71 is directly driven by shaft 18 of water turbine 80. Some or all of the discharge water out of the turbine could be utilized to cool the rotating tool and for the prevention of sparks.
FIG. 9 shows a 60 Hz electric generator 82 being driven by my high speed water turbine 80 via belt 81 using common speed reducing pulley arrangement with approximately 3:1 pulley diameter ratio for 3600 RPM or 6:1 pulley ratio for 1800 RPM. Frequency of 60 Hz can be maintained by employing suitable feedback control circuitry which adjusts the turbine water flow to match the load using techniques well known in the art.
FIG. 10 shows a common household garbage disposal rotor 92 driven directly by the turbine 80 utilizing pressurized household water supply to drive the water turbine. Discharge water out of the water turbine discharge passage 36 flows further into sink 93 flushing the chopped garbage through passage 94 and down the household drain. Turbine 80 is of the same configuration as shown in FIG. 1 and first described above, except the turbine nozzle passages 50 shown in FIG. 4 have small diameter of 0.10 inch instead of 0.13 inch. Standard household pressure of 50 psi will produce 1/3 horsepower in the speed range of 3000 to 5000 RPM and water flows of about 18 GPM.
Alternate turbine configurations, producing significantly higher shaft horsepower and utilizing the same basic turbine hardware as described above is shown on FIGS. 5B, 6B and 7B. The lower horsepower turbine nozzles configuration shown on FIGS. 5A and 6A incorporates nozzle body 16A and individual nozzles 50A having exit diameter identified as NA on FIG. 5A. The matching lower horsepower tubine wheel and the turbine blades are identified by numerals 26A and 19A respectively on FIG. 7A. The tip diameter of the lower horsepower turbine blades is identified as DA on FIG. 7A. The basic turbine blade configuration diameter identified as DB on FIG. 7A is generally larger than the diameter DA and is machined down to the diameter DA for a lower power version, while it can remain unchanged for a higher power version such as shown on FIG. 7B.
The basic nozzle body utilized for both versions is shown on FIGS. 5A and 6A and it can remain unchanged for the lower power version. For the higher power version the cylindrical portion of the individual nozzle diameter is increased from the dimension NA shown on FIG. 5A to a dimension NB shown on FIG. 5B while utilizing the same centerlines of the individual nozzles. As described above the typical nozzle passage geometry as shown as 50A on FIG. 5A consists of tapered hole at the entrence and leading into a cylindrical portion of the nozzle passages closely adjacent to each other at the nozzle exits. Therefore, an increase of individual nozzle diameters in those regions will cause interference of those passages and resulting in a breakage between the nozzle wall. To correct this undesirable effect, the nozzle body is machined in the axial direction by the amount shown as dimension L on FIG. 5B. The result of the aforemensioned operation will produce closely nested nozzles with larger flow areas as indicated by 50B on FIG. 6B. The turbine blades tip diameter DB on FIG. 7B is sized to match the larger nozzle shown on FIG. 6B. The objective of this design method is to affect minimum changes in the overall turbine configuration, thus the position of the bearings and the shaft remain unchanged for both versions. This dictates that the turbine wheel be machined in the axial direction by the dimension L shown on FIG. 7B, in order to compensate for the aforemensioned change of the nozzle body shown as dimensionL on FIG. 5B. The increase in the nozzle sizes utilizing the aforemensioned procedure to larger nozzles as shown in FIG. 6B changes the outer perimeter of the nozzle exits significantly, thus requiring a change in the matching turbine blades tip diameter from DA shown on FIG. 7A to diameter DB on FIG. 7B. However, the change on the inner permeter of the nozzle exits is minimal because of the compound effect of the nozzles centerlines spreading further apart from each other tending to increase the inner perimeter of the nozzles, while the increase inthe individual nozzle diameters tend to decrease the inner permiter of the nozzles.
For typical high efficiency turbines, the nozzle centerlines are positioned to the shaft centerline with an angle of 60 to 80 degrees (10 to 30 degrees with the turbine nozzle outlet surface) which incombination with an appropriate cone shape of individual nozzles allows for maintaining of relatively constant inner nozzles perimeter utilizing the above described procedure. Therefore, the turbine blades inner diameter shown as DI on FIGS. 7A and 7B which typically is somewhat smaller than the inner perimeter of the nozzles, can remain the same for both versions even if the inner perimeter of the nozzles changes slightly from one version to another. By this method, a relatively simple and inexpensive machining operations allow for utilization of standard premachined turbine nozzle bodies and premachined turbine wheels and blades, thus avoiding a relatively large expense associated with redesigning and retooling of the entire turbine and associated housings.
A higher turbine power output achieved by the above procedure should be matched by the same increase in power absorbed by the load. Standard methods well known in the art are used to provide such matching performance.
It should be understood that the form of the invention illustrated and described herein is intended to be representative only, as certain changes may be made therein without departing from the clear teachings of the disclosure. Acordingly, reference should be made to the following apended claims in determining the full scope of the invention. | 4y
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to an apparatus for applying a film to a floor surface and, more particularly, to an apparatus for applying a protective film to a carpet.
[0002] Polyethylene film has been used to provide protection for carpets and carpeted stairs. Typically the polyethylene has one side coated with a low-tack adhesive and comes in 24, 32 and 36-inch widths in rolls up to 1,000 feet long. Rolls are typically reverse wound so that the adhesive layer is on the outside of the roll. When the film is applied to a carpeted surface, the adhesive layer is applied to the carpet to hold the film in place.
[0003] Applying the film to a carpet must be done by manually unrolling the film on one's hands and knees or by using a single roller device with a handle. These methods prove difficult to apply the film without wrinkles and are not particularly suited to application on carpeted stairs.
SUMMARY OF THE INVENTION
[0004] Accordingly, a carpet film applicator is provided which includes a handle, film roller holder and front and rear rollers to flatten and smooth the film on a carpeted surface. A front guide straightens the film to reduce wrinkling. A pair of side stair guides automatically actuate when applying the film to stairs to smoothly apply the film.
[0005] The carpet film applicator may be used to apply a smooth plastic film to a carpeted surface by pushing the applicator along the floor. For stairs, the side support wheels automatically deploy to support the film applicator. With the weight of the applicator off of the front and rear rollers, the applicator may be pushed back against a stair to pull the film tightly against the stair. Once the film is pushed against the front of the stair, the applicator is lowered onto its front and rear rollers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of the carpet film applicator shown in operation on a flat surface.
[0007] FIG. 2 is a front elevational view of the carpet film applicator.
[0008] FIG. 3 is a side elevational view of the carpet film applicator.
[0009] FIG. 4 is a side elevational view of FIG. 3 with the side support wheels deployed.
[0010] FIG. 5 is an enlarged perspective view of the carpet film applicator.
[0011] FIG. 6 is a perspective view of the carpet film applicator shown in operation on stairs.
[0012] FIG. 7 is a side elevational view of FIG. 4 shown on a stair.
DETAILED DESCRIPTION
[0013] Referring to FIGS. 1 and 2 , the carpet film applicator of the present invention is generally indicated by reference numeral 10 . Film applicator 10 includes a frame 12 , a push handle 14 , an intermediate handle 15 and a film roll dispenser 16 which holds a film roll 18 . The film roll dispenser 16 allows the film roll 18 to freely turn to dispense the plastic film 20 . Plastic film 20 may be a polyethylene film with a low-tack adhesive backing to hold the film in place once it has been applied to a carpeted or other surface. Polyethylene film is widely used to protect carpeted surfaces because it is relatively thin and durable.
[0014] Front 22 and rear 24 rollers flatten the film 20 against the floor. A trailing roller 26 smoothes the film 20 and helps to tuck the film in against a stair. A front guide bar 28 helps keep the film 20 straight as it comes off roll 18 and is directed to roller 22 . Guide bar 28 is bowed outwardly to help prevent wrinkles in the film 20 when it is dispensed from roll 18 .
[0015] Referring to FIGS. 2-5 , side stair guides 30 and 32 are each slidably attached to frame 12 by a pair of bolts or pins 34 and 36 through slots 38 and 40 . The slots 38 and 40 allow the side stair guides 30 and 32 to move between a retracted position ( FIGS. 3 and 5 ) and an extended position ( FIG. 4 ). When in the retracted position, the bottom of wheels 42 and 44 of stair guides 30 and 32 are even with the bottoms of rollers 22 and 24 . When the guides 30 and 32 are in the extended position, the guides 30 and 32 hold the rollers 22 and 24 above the floor.
[0016] A pair of latch springs 46 and 48 , one on each side of applicator 10 , are attached at one end to frame 12 and at the other end to side stair guides 30 and 32 . When the latch springs 46 and 48 pull stair guides 30 and 32 down to the extended position, spring biased latch pins 50 and 52 extend an outboard of stair guides 30 and 32 and engage notches 54 and 56 . A chain or cable 58 links latch pins 50 and 52 to a rod 60 , with a release handle 62 . Rotating the handle 62 tightens the chain 58 to pull the latch pins 50 and 52 inwardly against the bias of springs 64 and 66 to disengage latch pins 50 and 52 from notches 54 and 56 .
[0017] Referring to FIGS. 1 and 3 , when operating the carpet film applicator 10 on a flat surface, the operator pushes on the handle 14 to move the applicator 10 . As the applicator 10 is pushed along, the plastic film 20 unrolls from film roll 18 . The plastic film 20 travels over the guide bar 28 and under front 22 and rear 24 rollers and trailing roller 28 and onto the flat surface. The operator walks over the film 20 as it is smoothly applied.
[0018] Referring to FIGS. 4-7 , when the carpet film applicator 10 is operated on stairs 70 , the front 22 and rear 24 rollers are extended over the edge of a stair such that only the trailing roller 26 is resting on the stair (See FIG. 7 ).
[0019] When the weight of applicator 10 is no longer on the side stair guide wheels 42 and 44 , the latch springs pull the side stair guides 30 and 32 downwardly to the extended position. The spring biased latch pins 50 and 52 extend through notes 54 and 56 .
[0020] The applicator 10 is then pushed over the edge of the stair 70 and lowered to rest on the next lower stair. The operator may grasp the intermediate handle 15 to help lower the applicator 10 . The applicator 10 rests on the side stair guide wheels 42 and 44 which hold the applicator 10 off of the front 22 and rear 24 rollers and trailing roller 26 . The applicator 10 may be pulled backward to tuck the film 20 into the nap of the stair 70 . The operator then grasps the release handle 62 and turns the rod 60 to release the latch pins 50 and 52 . When the latch pins 50 and 52 clear the notches 54 and 56 , the applicator drops to the rollers 24 and 26 and the film 20 may now be applied to the next stair.
[0021] In the preferred embodiment, 24, 30 and 36-inch rolls of film may be applied, although other widths may also be applied. The front and rear rollers 22 and 24 may be constructed of rubber or other material to flatten the film 20 . Handle 14 may be adjustable to allow for different positions depending on operator height or for use on stairs. Additionally, the applicator 10 may include a bar (not shown) which may be actuated by a lever (not shown) or by the handle 14 , which is lowered behind the trailing roller 26 to tuck in the film against a stair.
[0022] It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto, except in so far as such limitations are included in the following claims and allowable equivalents thereof. | 4y
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RELATED APPLICATIONS
The present application claims priority to European Patent Application filed on Feb. 27, 2012 with application number 12157059.2, the entirety of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to an engine attachment pylon for attaching an aircraft engine to a fuselage of an aircraft.
A known engine attachment pylon of this type is described in FR2943623 (U.S. Published Application 2012/0066937). It is an object of this invention to provide an improvement of an engine attachment pylon as described in FR2943623 (U.S. Published Application 2012/0066937).
SUMMARY OF THE INVENTION
According to the first aspect of the invention there is provided an engine attachment pylon, for mounting an aircraft engine to an aircraft structure, comprising a rigid structure housing a dynamic mass absorber which is tuned to absorb vibrations of the aircraft engine; the rigid structure substantially forming a box and comprising a first and a second attachment means to connect the engine and the fuselage respectively.
According to a second aspect of the invention there is provided an engine attachment assembly comprising a rear portion of an aircraft fuselage, two aircraft engines, and two engine attachment pylons wherein each engine attachment pylon connects each engine to the fuselage and wherein the engine attachment pylons according to any of the preceding claims are arranged such that the engine attachment pylons are joined on a vertical plane (P) within the aircraft fuselage by a junction.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example with reference to the accompanying drawings, of which:
FIG. 1 is a perspective view of a rear portion of a fuselage having two engines attached to it by means of two engine attachment pylons;
FIG. 2 is a similar view as FIG. 1 showing a dynamic mass absorber located inside each engine attachment pylon according to the present invention; and
FIG. 3 is a detailed view of the resonator according to arrow F of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 , there is shown a rear portion of a fuselage 10 of an aircraft having a central longitudinal axis (x). The description will be made using a conventional axis system, comprising a longitudinal (x), a horizontal (y), and a vertical (z) axis. The rear portion of the fuselage 10 comprises two engines 11 , 12 each having a central longitudinal axis (a) parallel to the longitudinal axis (x) of the fuselage 10 . In this example, each engine comprises a nacelle 13 , 14 for housing a compressor and combustion chamber, and a pair of counter rotating open fan blades 15 , 16 providing thrust to the aircraft. Each engine is attached to the fuselage by means of an engine attachment pylon 17 , 18 . Each engine attachment pylon comprises a rigid structure 19 covered by aerodynamic fairings, in particular a front fairing 20 which forms a leading edge and a rear fairing 21 which forms a trailing edge of the pylon. With reference to FIG. 3 , the rigid structure 19 forms substantially a box, which comprises a front spar 22 , a rear spar 23 , connected together by a first plate attachment means 24 and a second plate attachment means 25 extending perpendicularly between each spar, and sealed with an upper 26 and a lower panel 27 . With reference to FIG. 2 , both rigid structures 19 are joined together on a vertical plane (P) passing through the longitudinal (x) axis of the fuselage 10 by a junction 28 . Each rigid structure passes through openings in the fuselage, as explained in FR2943643 (U.S. Published Application 2012/0066937) and incorporated in the present description by reference. In this example, the rigid structures are raised by 30° from the horizontal (y) axis. The engine attachment pylons 17 , 18 interface at the uppermost edge second structural members so as to form the junction 28 which is substantially a hinge. The first attachment means 24 is conventionally rigidly attached to the engine nacelle. The rigid structure 19 is attached to the fuselage 10 internally by means of struts, as explained in FR2943643 (U.S. Published Application 2012/0066937), but not shown in the figures.
The engine attachment pylon 18 further comprises a dynamic mass absorber 29 , or resonator, as shown in FIGS. 2 and 3 , according to the present invention, housed within the rigid structure 19 . The terms dynamic mass absorber and resonator may be used interchangeably. With reference to FIG. 3 , the resonator 29 comprises a damping member 30 attached at one end to the second attachment means 25 and movably attached at the other end to a load transfer means 31 . The load transfer means comprises 31 a lever 32 pivotally mounted around a pivot 33 and attached at one end to the damping member 30 and a fitting 34 at the other end. The fitting 34 attaches the lever 32 to the first attachment means 24 . The damping member 30 has a narrow width compared to its length and extends, in-use, in the direction between the engine 11 and the fuselage 10 . The damping member 30 comprises a lumped mass 35 , or suspended ring mass, which is preferably located in the vicinity of the first attachment means 24 . The pivot 33 is preferably a ball joint attaching the lever 32 to the end of a fixed member 36 , having a narrow width compared to its length and which is attached at its other end to the second attachment means 25 .
During flight and operation of the engines, vibrations comprising bending (B), torsion (TO), and tension (TE) and compression (C), as illustrated in FIG. 1 , will be induced and transferred to the fuselage. The bending and torsion vibrations are attenuated by an arrangement of struts, which are not illustrated in the figure but are explained in FR2943643 (U.S. Published Application 2012/0066937). The struts serve to support the engine attachment pylons 17 , 18 and reduce bending and torsion vibrations induced into the engine attachment pylon by the operation of the engine 11 , 12 and during flight. The tension and compression vibrations in this example are attenuated by the resonator 29 . Tension and compression vibrations are experienced by the fitting 34 , and subsequently transferred to the damping member 30 by inducing oscillatory rotations in the lever 32 around the pivot 33 . Then, the amplitude of the displacements at the attachment point of the damping member 30 to the lever 32 is attenuated by the inertia of the lumped mass 35 , or ring mass, mounted onto the damping member 30 , thus acting altogether as a damping force. The size of the ring mass 35 is chosen so that the dynamic mass absorber 29 can dissipate or absorb the vibration of the engine 11 , 12 . In particular, the weight of the lumped mass 35 is determined as a function of the amount of force required to react against the frequency of the vibrations seen at the location of the fitting 34 .
The principal advantage of this invention is to provide an engine attachment pylon 17 , 18 which prevents tension and compression vibration from the engines 11 , 12 from propagating into the cabin area of the fuselage. Also, the use of the junction 28 in the present invention minimizes any vibrations from one engine attachment pylon 17 from propagating into the other engine attachment pylon 18 . This is achieved because the junction 28 forms a hinge which isolates the movement from one engine attachment pylon 17 to the other 18 .
Another advantage of this invention is that the position of the lumped mass 35 being located in the vicinity of the first attachment means 24 prevents bending vibrations from being induced into the engine attachment pylon 17 due to the existence of the resonator 29 . Also, by implementing a lumped mass 35 as the means of damping, there is a reduced maintenance burden due to there being no moving parts and no hydraulic leakage.
Alternatively, the lumped mass 35 could be replaced by a hydraulic damper. The pivot 33 may also be changed such that it is not a fixed member 36 having a narrow width compared to its length and extending to the second structural member 25 , but takes the form of a rigid strut attached between the upper 26 and lower panels 27 , at the location of the pivot 33 .
It will be appreciated that engine attachment configurations other than a rear mounted configuration with two engines mounted on engine attachment pylons 17 , 18 raised by 30° from the horizontal (y) axis of an aircraft fuselage are possible. The engine attachment pylon according to the present invention could easily be adapted for other configurations. One such configuration would be to attach the second structural member to the fuselage. In this case, there is no need for a junction connecting the two engine attachment pylons and it would be appreciated that there would be a reduction in structural mass as a result. The engine attachment pylon could also be relocated to beneath the wing. In this case, the resonator within the engine attachment pylon would extend vertically in the direction between the engine and the wing.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the identification, isolation and use of markers and antibodies which recognize these markers in the diagnosis of invasive prostatic neoplasia in humans, and to diagnostic aids for screening biological samples for evidence of invasive prostatic neoplasia.
2. Description of the Background
The prostate, an organ of the mammalian male urogenital system, is located at the base of the bladder surrounding the urethra. Although encapsulated, the walnut-sized prostate can be divided into five lobes, the posterior, middle, and exterior lobes and two lateral lobes. Histological examination reveals that the prostate is a highly microvascularized gland comprising fairly large glandular spaces lined with epithelium. The majority of fluid of the male ejaculate is supplied by this gland and the seminal vesicles.
The prostate is an endocrine-dependent organ which responds to both the major male hormone, testosterone, and the major female hormones, estrogen and progesterone. In particular, the testicular androgen is believed important for prostate growth and development because, in both humans and other animals, castration leads to prostate atrophy and an absence of any incidence of prostatic carcinoma.
There are two major neoplasia of the prostate, benign enlargement of the prostate or nodular hyperplasia (also called benign prostatic hyperplasia (BPH) or benign prostatic hypertrophy), and prostatic carcinoma. Nodular hyperplasia is very common in men over the age of 50. It is characterized by the presence of a number of large distinct nodules in the periurethral area of the prostate. Although benign, these nodules can produce obstruction of the urethra causing nocturia, micturition, and difficulty in starting and stopping a urine stream upon voiding the bladder. Occasionally, catheterization is required and even surgery. In the more extreme cases, secondary changes in the bladder can occur such as hypertrophy, acute retention with secondary urinary tract involvement, azotemia and uremia. Although all of these changes of the prostate may suggest pre-malignancy, there is as yet no direct association between nodular hyperplasia and prostatic carcinoma.
Carcinoma of the prostate is the most common form of cancer in human males with upwards of one third of those cases being fatal. In the more aggressive forms, transformed prostatic tissue escapes from the prostate capsule invading locally and throughout the bloodstream. Local invasions typically involve the seminal vesicles, the base of the urinary bladder, and the urethra. Hematogenous spread occurs primarily to the bones and lymph nodes, but can include massive visceral invasion as well. Histologically, most lesions are adenocarcinomas with well-defined gland patterns, but the more typical malignancy patterns associated with the very aggressive cancers are also common. Except in rare instances, all forms of prostatic carcinoma originate in the peripheral zone of the gland which is palpable upon rectal examination.
Prostatic carcinomas are graded and staged by number and letter according to histological criteria, the arrangement and appearance of malignant glands, and the degree of anaplasia of the cancerous cells. Stage A1 tumors include the incidental or clinically unsuspected cancers. These are detected in autopsy and rarely pose a problem to the patient. Stage B tumors are detectable by rectal digital examination and are also confined to the prostate. Tumors classified as B1, B2, and so on, indicate increasing severity of tumor formation. These tumors are fairly common in older men who begin to show signs and symptoms characteristic of some form of prostatic carcinoma. Stage C tumors have breached the prostate capsule and may or may not have invaded the surrounding tissues such as the seminal vesicles. Those tumors which have seminal vesicle involvement show an 80% correlation with lymph node involvement (C2). Stage D tumors have distinct metastases and a 100% correlation with lymph node involvement. Over 75% of patients with prostatic carcinoma show signs of stage C or D type development with significant urinary tract involvement. Only 5-10% of stage A patients, of those who have been followed for 8-10 years, develop stage C or D type prostatic carcinoma although the probability increases for patients who first :present at a fairly young age. Young males with nodular hyperplasia are typically recommended for surgery or more aggressive endocrine therapy.
Little is known about the causes of prostatic carcinoma, but there are at least three confirmed risk factors--age, race and endocrine system. As discussed, the incidence of all forms of prostatic neoplasia is very high in men over 50. In the 45-49 year old age group the incidence is about 4.8 per one hundred thousand men and increases to 513 between the ages of 70 to 75. The incidence of latent carcinoma is higher still. Over 30% of prostate tissue in autopsied males over 50 shows some sign of latent carcinoma.
The second risk factor, race, is fairly strong. Among white males in the United States the incidence of prostatic neoplasia in those over 50 is about 58 per one hundred thousand men. The rate increases to about 95 per one hundred thousand in black males whereas in oriental males, prostatic neoplasia is rather rare at about 3 to 4 per one hundred thousand in one study performed in Hong Kong. The exact reason for this distribution is unclear. Although environmental effects should not be discounted, epidemiology points to a strong genetic influence.
The final risk factor, the endocrine system, may be the most important. Although, no direct link has been established between absolute or relative levels of any hormone and neoplasia of the prostate, the evidence for some form of hormonal regulation is convincing. First, in both humans and dogs, the only other mammal known to develop hyperplasia with aging, nodular hyperplasia or full-blown carcinoma of the prostate only develop in the presence of intact testes. Secondly, in castrated young dogs it is possible to induce nodular hyperplasia by administering of androgen and estradiol, suggesting that hormones produced by the testes are required for prostate development. Further, there is some evidence that dihydrotestosterone, which is derived from testosterone, may be the ultimate mediator of cell growth. Prostate cells of the epithelium are covered with dihydrotestosterone receptors which increase in number in the presence of estrogen. In men and dogs, plasma testosterone levels decrease and estradiol levels increase with age. This alteration shifts the hormonal balance of the cells and possibly sensitizes the prostate for transformation. At the very least, it appears that androgens are required to maintain the viability of prostate epithelium from which most carcinomas derive.
Yearly rectal examination is very useful for the early detection of prostatic neoplasia. This detection method is fairly simple and straightforward. However, it is subject to bias and not very well standardized. At the earliest, it can only detect stage B carcinoma and has no capacity to determine whether stages C or D are developing. Further, the digital rectal exam is not very sensitive. Approximately 30-60% of men have a prostatic neoplasia that cannot be detected by the physician, which is further complicated by the fact that these men usually present with no symptoms at all. A number of new techniques look promising. These include ultrasound and other methods of noninvasive detection such as positron emission tomography (PET). These methods are limited to the detection of formed tumors and are unable to detect prostatic carcinoma which is just beginning to invade surrounding tissue.
Chemotherapy, surgery or radiotherapy is the treatment of choice for stage A or B prostatic neoplasia. Surgery involves complete removal of the entire prostate, radical prostatectomy, and often removal of the surrounding lymph nodes, lymphadenectomy. Radiotherapy may be either external or interstitial using 125 I and is typically performed in conjunction with surgery. Endocrine therapy is the treatment of choice for more advanced forms. The aim of this therapy is to deprive the prostate cells, and presumably the transformed prostate cells as well, of testosterone. This is accomplished by administering estrogens or synthetic hormones which are agonists of luteinizing hormone-releasing hormone (LHRH). These cellular messengers directly inhibit testicular and organ synthesis and suppress luteinizing hormone (LH) secretion which in turn leads to reduced testosterone secretion by the testes. Despite the advances made in achieving a pharmacologic orchiectomy, the survival rates for those with stage C and D carcinomas are rather bleak. In the short term, the most promising results will be achieved by earlier detection using more sensitive assays.
Carcinoma cell invasion of the seminal vesicles is a very poor prognosis for the patient. As discussed, seminal vesicle involvement frequently correlates with metastases to the lymph nodes and subsequent dissemination throughout the body. Invasion of the seminal vesicles begins with cell multiplication at the base of the prostate. Transformed cells expand within and through the ejaculating duct, localizing in the seminal vesicles near their point of junction with the vas deferens (A. A. Villers et al., J. Urol. 143:1183, 1990). Surprisingly, others have found a relatively low frequency of positive nodes in patients with seminal vesicle invasion, but a comparable prognosis among patients with and without lymph node metastases (E. Mukamel et al., Cancer 59: 1535, 1987). No alternative explanation was proposed. Uncertainty in these results may stem from the fact that the seminal vesicles are not very well defined morphologically or biochemically.
There are two seminal vesicles in man, one located on each side of the urethra posterior to the urinary bladder and superior to the prostate. They are believed to contain two types of epithelial cells, principal or superficial cells, and basal cells. Each gland is open to the urethra and comprises a highly convoluted tube coiled upon itself which, if extended, would be approximately 15 cm in length. The convolutions within each gland impart a honeycomb appearance when viewed under cross section. The internal cells of the individual vesicles are highly interconnected with ridges and folds both circular and longitudinal. Individual cells of the walls contain numerous secretory bodies including golgi vacuoles, electron dense granules and droplets. These bodies secrete a mixture of materials into the lumen of each tubule. Approximately 70% of human ejaculate is composed of this material which contains fructose, citrate, inositol, prostaglandin, choline esters, and a number of soluble proteins. A few of these proteins have been identified as specific to seminal vesicle tissue including semenogelin I, a large molecular weight protein which can be broken down into three subunits of 52 kDa, 71 kDa, and 76 kDa (H. Lilja et al., J. Biol. Chem. 264:1894, 1989), semenogelin II (H. Lilja and A. Lundwall, Proc. Natl. Acad. Sci. USA 89:4559, 1992), lactoferrin or scafferin (A. Hekman and P. Rumke, Fertil. Steril. 20: 312,1969), seminal vesicle specific antigen (SVS A), MHS-5 specific antigen (J. C. Herr et al., J. Reprod. Immunol. 16:99, 1989), rat seminal vesicle specific (SVS) proteins I-VIII (J. Seitz and G. Aumuller, Andrologia 22:25, 1990), B-microseminoprotein (B-MSP) (K. Akiyama et al., Biochim. Biophys. Acta 829:288, 1985), and seminal plasma number 7 antigen (K. Koyama et al., J. Reprod. Immunol. 5:134, 1983). These proteins and antigens are only now being analyzed in detail and some have been cloned by recombinant DNA techniques.
Fairly recently, a number of serum antigens have been characterized as markers for prostatic neoplasia. These markers are useful because they are relatively straightforward to assay using noninvasive procedures and may detect prostatic neoplasia at very early stages of development. Both malignant and normal prostate epithelial cells were found to express a prostate-specific acid phosphatase (PAP) which is detectable in serum by biochemical and other immunological techniques. Elevated PAP levels correlate well with neoplasia that has spread beyond the prostate capsule. Consequently, PAP is a useful serum marker for characterizing the later stages of prostatic neoplasia and also for monitoring the progress of the disease in patients.
Another marker which has proved to be of value is the prostate-specific antigen (PSA), a serine protease found in both normal and neoplastic prostate epithelium. Investigations have determined that there is a direct correlation between serum PSA levels with the size and stage of a tumor. The normal concentration of PSA in men is from 0 to 2.8 ng/ml of serum. In one study, researchers determined that average PSA concentrations in the serum of patients grouped according to severity were proportional to the clinical state of the tumor (T. A. Stamey, et al., N. Engl. J. Med. 317:909, 1987). These authors did not indicate whether PSA levels could be used to determine the pathological stage of carcinoma in individual patients. Concentrations of 40 ng/ml were predictive of advanced stages of disease, but the predictive value of serum concentrations of less then 15 ng/ml were less than clear. PSA titers were only marginally useful to distinguish whether the tumor was contained by or had escaped the prostate. Levels greater than 10 ng/ml were typical in patient groups with more advanced and gland-unconfined carcinomas. However, it was not atypical to find high PSA levels in patient groups with gland-confined hyperplasia.
These theories were partly confirmed in a more recent study which looked at serum PSA levels in 209 men with various stages of prostatic neoplasia (T. E. Osterling et al., J. Urol. 139:766, 1988). These authors determined that PSA levels showed a statistically significant correlation with pathological stages when compared within the various groups. However, the levels were far less useful when looking at patients on an individual basis. There was a large degree of variability between patient groups and a significant number of both false and missed positives. In a rigorous analysis using greater numbers of men and taking into account actual or predicted numbers of carcinoma cells, Partin et al. determined that serum PSA levels were influenced by tumor volume and the stage of differentiation (A. W. Partin et al., J. Urol. 143:747, 1990). Mean antigen levels increased with advanced pathological stage, but this seemed to be related more to overall tumor volume than to any particular stage of the disease. In fact, immunohistochemical studies revealed that higher stage tumors actually produced less PSA, possibly due to the diseased state of the cells. The authors concluded that PSA levels are unreliable for preoperative prediction of the pathological stage of individual patients.
A number of other prostate antigens have since been identified. The most well-studied of these has been the prostatic carcinoma associated complex (PAC) also called the glycoprotein complex (G. L. Wright et al., Int. J. Cancer 47:717, 1991). Although specific for prostatic epithelium, this protein complex of 35-310 kDa antigens was not correlative for the staging of prostatic carcinoma.
SUMMARY OF THE INVENTION
The present invention overcomes the problems and disadvantages associated with current strategies and designs and provides a new method for stagespecific detection of prostatic neoplasia in a patient.
As broadly described herein, one embodiment of the invention is directed to a method for identifying, isolating, and using markers derived from non-prostatic tissues such as the seminal vesicles in the detection of prostatic neoplasia in a patient. The marker may comprise a protein or an antigenic part of a protein. This invention also encompasses the identification, isolation and cloning of the gene or genes which code for the specific marker. The recombinant gene or genetic sequence is used to express recombinant marker or antigenic parts of the marker.
As broadly described herein, another embodiment of the invention is directed to methods for the identification and isolation of antibodies to seminal vesicle-specific markers and other non-prostatic markers in biological samples. Marker is incubated with a biological sample taken from a patient suspected of having prostatic neoplasia. The sample may be tissue, blood, urine, or semen. The amount of serum-derived antibody which binds to the marker is determined and, if over a predetermined base level, indicates the presence of specific antibody in the sample and prostatic neoplasia in the patient.
As broadly described herein, a further embodiment of the invention is directed to an antibody which specifically binds to the marker and to a method for using this antibody to detect prostatic neoplasia in a patient. The antibody may be a monoclonal or polyclonal antibody or a fragment of a monoclonal or polyclonal antibody such as an Fv fragment and preferably the antibody is an IgG isotype. In one aspect of the invention the specific antibody is incubated with a biological sample taken from the patient suspected of having prostatic neoplasia. The sample may be tissue, blood, urine, or semen. The amount of specific marker in the sample which binds to the antibody is determined and if over a predetermined base level indicates the presence of specific marker in the sample and prostatic neoplasia in the patient.
As broadly described herein, a still further embodiment of the invention is directed to diagnostic kits for the detection of prostatic neoplasia in a patient comprising the marker or the marker-specific antibody and methods for using these markers and antibodies for the detection of prostatic neoplasia.
Other objects and advantages of the invention are set forth in part in the description which follows, and in part, will be obvious from this description, or may be learned from the practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 Diagrammatic representation of a fractionation protocol for seminal vesicle tissue.
FIG. 2A Ponceau S stained nitrocellulose membrane of electrophoretically separated fractions of seminal vesicle tissue homogenate. Pr-F=prostate fluid collected at prostatectomy.
FIG. 2B Ponceau S stained nitrocellulose membrane of electrophoretically separated fractions of seminal vesicle tissue homogenate after excision of specific bands.
DESCRIPTION OF THE INVENTION
To achieve the objects and in accordance with the purposes of the invention, as embodied and broadly described herein, the present invention comprises markers, parts of markers, genes and genetic sequences which encode these markers, both monoclonal and polyclonal antibodies and parts of antibodies, and diagnostic kits for the detection of prostatic neoplasia in a patient.
Neoplasia of the prostate can be divided into two basic forms, nodular hyperplasia and carcinoma. Nodular hyperplasia is not a serious health concern. For those with asymptomatic hyperplasia, no treatment is necessary. For those with symptomatic hyperplasia of the prostate, therapy typically involves chemotherapeutic drugs, radiation therapy, or radical prostatectomy. Prostatic neoplasia only becomes life threatening when transformed prostate cells break through the prostate capsule and metastasize throughout the body. Therefore, it is the invasion-proficient status which is most important in the detection of this disease.
The seminal vesicles are often invaded by prostatic carcinoma cells. Upon invasion this normally highly organized and compartmentalized structure becomes damaged. Damage due to physical disruption of the seminal vesicles results in the presentation of novel seminal vesicle-derived markers to the blood stream and other bodily fluids. In one aspect of the invention, these disrupted and damaged cells passively release seminal vesicle-specific macromolecules, or markers, which may be proteins, cytokines, modified proteins, peptides, complex biochemicals, fragments of proteins or peptides, nucleic acids, or modifications or combinations thereof, to areas of the body such as, for example, the bloodstream. In another aspect, the damaged and "leaky" vasculature produced by the invading carcinoma leads to the direct release of seminal vesicle secretions into areas of the body such as, for example, the semen, urine or bloodstream. In either situation, once released, these markers may be detectable by biochemical techniques known to those of ordinary skill in the art.
These seminal vesicle-derived markers are also likely to be highly antigenic. The patient's lymphocytes will produce antibodies specific to these "newly-recognized" seminal vesicle-derived antigens. Although the seminal vesicles are not foreign to the patient, antigens released have not previously been exposed to the host's immune system and could stimulate a humoral or cellular response. These host-derived, antigen-specific antibodies and/or antigen-primed cells may also be detectable by biochemical techniques known to those of ordinary skill in the art. Upon detection and quantitation, the absolute or relative amounts of seminal vesicle-specific antigens or antibodies may be determinative of a particular stage of prostatic neoplasia. These results may be used alone or in combination with PAP and/or PSA titers to select or rule out a course of therapy for a patient.
A first embodiment of the invention is directed to the identification of seminal vesicle-specific markers, which may be proteins, cytokines, modified proteins, peptides, complex biochemicals, fragments of proteins or peptides, nucleic acids, or modifications or combinations thereof, and are useful for the detection of prostatic neoplasia. First, seminal vesicle-specific markers are identified and isolated. For example, seminal vesicles or tissue samples containing seminal vesicle-specific markers such as blood, semen, or urine are obtained. In a direct approach, seminal vesicle tissue is isolated by necropsy from, for example, human cadavers or by radical prostatectomy. Samples may be used immediately or frozen to -80° C. for later use.
Samples are fractionated by, for example, chromatography, such as ion-exchange or affinity column chromatography, salt fractionation using for example ammonium sulfate precipitation, centrifugation, size and chemical fractionation, SDS-polyacrylamide gel electrophoresis (PAGE) run under reducing or non-reducing conditions, or filtration. Using such techniques, particular fractions or extracts containing, for example, the glycoprotein-rich secretory markers, can be targeted. Alternatively, or in addition to these procedures, more rigorous techniques can be used to isolate single markers or antigens or groups of markers, such as high-performance liquid chromatography (HPLC), reversed-phase HPLC, ion exchange HPLC, fast-phase liquid chromatography (FPLC), one-, two-, or three-dimensional electrophoresis followed by electro-elution or electrotransfer of the markers of interest from the electrophoresis matrix onto a membrane such as a nitrocellulose membrane. These and other so-called conventional techniques for the isolation of proteins and peptides are described in Proteins: Structures and Molecular Properties (T. E. Creighton, Freeman and Co., N.Y., 1984), and A Practical Guide to Protein and Peptide Purification for Micro Sequencing (P. T. Matsudaira, Academic Press, N.Y., 1989), which are hereby specifically incorporated by reference.
In an indirect-approach, seminal vesicle tissue can be used to create antibodies specific to seminal vesicle markers which are used to identify and isolate those antigenic markers. For example, seminal vesicle tissue or biological samples from patients with suspected or confirmed cases of some form of prostatic neoplasia are treated to isolate fractions which are likely to contain seminal vesicle-specific markers. These include, for example, fractions of cell surface antigens, glycoproteins, and lipoproteins, or fractions of cells disrupted to release membrane-associated and cytoplasmic antigens. Each of these fractions is injected into a female laboratory animal, such as a rabbit, a guinea pig, a rat or a mouse, to create seminal vesicle-specific polyclonal or monoclonal antibodies. Female animals are chosen as these are believed to have the lowest probability of containing anti-seminal vesicle antibodies and the highest probability of generating a strong immune response. After injection and possibly the administration of booster injections, blood is collected and polyclonal antisera and/or antibodies are isolated from the serum. If necessary, seminal vesicle specific antibodies can be purified using, for example, affinity chromatography.
Monoclonal antibodies are also prepared. About three to four weeks after the initial injections, spleen cells are isolated, fused with myeloma cells of the same or a different species, such as for example, the murine cell lines P3-X63 Ag8, X63Ag.653, SP2/0-Ag14, FO, NSI/1-Ag4-1, NSO/1, and FOX-NY, or the rat cell lines Y3-Ag.1.2.3, YB2/0, and IR983F, and screened for hybridomas which express seminal vesicle-specific monoclonal antibodies. Hybridomas expressing human antibody or mostly human antibody can be creating by fusing the spleen cells obtained with human myeloma or human heteromyeloma cells such as, for example, U-266, FU-266, and HFB-1. A fusion procedure which employs polyethylene glycol or Epstein-Barr virus is preferred. Methods for the creation of antigen-specific polyclonal and monoclonal antibodies are disclosed in Antibodies: A Laboratory Manual (E. Harlow and D. Lane, Cold Spring Harbor, 1988). These antibodies are used to detect markers which are specific to seminal vesicles by immunoprecipitation, immunoblotting, such as Western blotting of electrophoresed seminal vesicle-specific antigens, or affinity chromatography.
Alternatively, seminal vesicle-specific markers, which may be purified, partially purified, or recombinantly produced, can be used to identify and isolate seminal vesicle-specific antibodies in, for example, the blood stream of patients. Seminal vesicle-specific markers are coupled to a matrix such as, for example, sepharose, sephadex, sephacel, or sephacryl, using techniques which are known to those of ordinary skill in the art. Whole blood or preferably blood plasma is subjected to, for example, affinity column chromatography using the antigert-coupled matrix. Fractions comprising seminal vesicle-specific antibodies are eluted and further purified using affinity chromatography with a purified antigen-coupled matrix or using conventional techniques such as differential centrifugation or other known separation techniques.
Seminal vesicle-specific markers which are identified and isolated, at least partially, are characterized. Their molecular weight is determined by, for example SDS-PAGE. The isoelectric point is determined by 2-dimensional PAGE techniques such as isoelectric focusing. The amino acid sequence is determined by, for example, partial digestion of the purified antigen, if necessary, automated sequence analysis of the digestion products, and reconstruction of the complete sequence from the resulting data. The presence or absence of lipids, carbohydrates, unusual amino acid residues, polysaccharide and other modifications is also determined. From knowledge of the complete sequence of a macromolecule, such as a protein or peptide, hydrophobicity-hydrophilicity charts can be determined, particularly antigenic regions identified, and three-dimensional structures predicted. Once characterized, these markers are compared with other known seminal vesicle-specific molecules either by computer sequence alignment analysis or by direct comparison of know features and, if necessary, side-by-side characterization.
With knowledge of even a portion of the amino acid sequence of the marker, it is possible to determine the genetic sequence with codes for the entire marker and to clone this sequence from the cellular genome or chemically synthesize all or part of the gene. To clone the gene, a genomic or cDNA library is created and probed with the genetic sequence of interest, which may be chemically synthesized or isolated from a genetic library. Positive clones are picked, expanded, and expressed to identify their products. In this fashion, an entire gene can be cloned from a cellular genome and expressed in a recombinant expression vector. Alternatively, using polyclonal or monoclonal antibodies, cDNA expression libraries can be probed for seminal vesicle-specific markers directly. The positive clones are identified, expanded, and their recombinant DNA sequences subcloned using techniques which are well known for those of orclinary skill in the art such as, for example, those described in Current Protocols in Molecular Biology (F. M. Ausubel et al., Green Publishing Assoc. and Wiley-Interscience, 1989), and Molecular Cloning: A Laboratory Manual, 2 nd Ed. (J. Sambrook et al., Cold Spring Harbor Laboratory, N.Y., 1989), which are hereby specifically incorporated by reference. Recombinant vectors containing all or specific antigenic portions of the gene of interest are created and used to produce large quantities of recombinant expression product in prokaryotes, such as, for example, E. coli, eukaryotes such as, for example, Bacculovirus, plant cells, or animal cells, or yeast cells. The amino acid sequence of the gene of interest is also synthesized chemically to produce large quantities of marker and to isolate additional marker.
Markers, including antibodies, antigens, and antibody or antigen fragments produced accordingly are useful in diagnostic kits for the detection of invasive prostatic neoplasia. As discussed, invasive prostatic neoplasia may be associated with release of seminal vesicle-specific antigens into areas of the body which do not normally receive these antigens, such as, for example, the bloodstream, the bladder, or the passageways of the male urogenital system such as the vas deferens, the bulbourethral gland, or the urethra. A sample of biological fluid, such as, for example, a tissue sample, or a sample of biological fluid such as semen, urine or blood, taken from the patient suspected of having prostatic neoplasia is analyzed for the presence or the increased presence of one or more of these seminal vesicle-specific markers or antigens or for the presence or increased presence of human antibodies directed against such markers or antigens.
Another embodiment of the invention is the analysis of samples of tissue or biological fluid obtained from patients suspected of having prostatic neoplasia for the presence of seminal vesicle-specific antigens as markers for invasive prostatic neoplasia. Useful assays include, for example, an enzyme immune assay (EIA) such as an enzyme-linked immunosorbent assay (ELISA), a radioimmune assay (RIA), a Western blot assay, or a slot blot assay. Briefly, samples of biological fluid believed to contain one or more markers of invasive prostatic neoplasia are incubated with seminal vesicle-specific antibody prepared according to the invention. The antibody may be of any isotype including IgG 1 , IgG 2a , IgG 2b , IgM, IgA, or IgD, but an IgG is preferable. Optionally, the antibody, which may be polyclonal, monoclonal, or a fragment of a monoclonal or polyclonal antibody, preferably the Fv fragment, may be fixed to a solid support to facilitate washing and subsequent isolation of the complex. Examples of solid supports include glass or plastic such as, for example, a tissue culture plate, a vial, a microtiter plate, a stick, a paddle, a bead, or a microbead. After incubation, the mixture is washed and the amount of antibody-antigen complex formed determined. This is accomplished by incubating the washed mixture with a second, labeled antibody which is specific to the complex. This second antibody may be a monoclonal or polyclonal antibody and is labeled with a detectable label. Examples of detectable labels include a radio isotope, a stable isotope, a fluorescent chemical, a luminescent chemical, a metal, an electrical charge, an enzyme, a chromatic chemical, a spatial chemical, an electron-dense molecule, or a label detectable by mass spectrometry. Alternatively, the amount of seminal vesicle-specific antigert in the sample may be determined using an indirect assay, wherein, for example, a second, labeled antibody is used to detect bound seminal vesicle-specific antibody, and/or in a competition or inhibition assay wherein, for example, a monoclonal antibody which binds to a distinct epitope of the antigen are incubated simultaneously with the mixture. Each of these assays are well known to those of ordinary skill in the art and described in, for example, Antibodies: A Laboratory Manual.
In another embodiment of the invention, a biological sample is taken from a patient suspected of having prostatic neoplasia and assayed for the presence of host antibodies to seminal vesicle-specific antigens. Useful assays include, for example, an RIA, an EIA such as an ELISA, a Western blot or a slot blot. As discussed, seminal vesicle antigens may be released into the body or blood stream upon invasion of transformed prostatic cells. These antigens may be recognized as foreign by the immune system of the body and anti-antigen antibodies produced. These host antibodies can be specifically detected using a diagnostic kit which comprises one or more purified or partially purified seminal vesicle-specific markers. As before, the assay to detect these antibodies can be a direct, indirect, competitive or inhibition assay. The assay may comprise polyclonal antibodies or fragments of polyclonal antibodies, such as the Fv fragment, or monoclonal antibodies or fragments of monoclonal antibodies, such as the Fv fragment, either of which are labeled with a detectable label such as, for example a radio isotope, a stable isotope, a fluorescent chemical, a luminescent chemical, a metal, an electrical charge, an enzyme, a chromatic chemical, a spatial chemical, an electrondense molecule, or a label detectable by mass spectrometry. The antibodies to be detected may be of any isotype including IgG, IgG 2a , IgG 2b , IgM, IgD, IgA, or a combination of these isotypes. Isotype specific anti-antibodies may also be utilized to identify or quantitate specific antibody isotypes.
In a direct assay, it is preferable that the seminal vesicle-specific antigens or antigenie fragments be produced recombinantly, although as discussed, antigens can also be produced synthetically or isolated and purified by convention techniques. It is preferred that the marker, or antigen, be fixed for a solid support such as, for example, glass or plastic such as a tissue culture plate, a vial, a microtiter plate, a stick, a paddle, a bead, or a microbead. A biological sample suspected of containing marker-specific antibody is added to the fixed antigen or marker and incubated, for example, between one hour and overnight: in phosphate-buffered saline (PBS), at between 4° C. and 37° C., preferably at about room temperature. After incubation, the mixture is removed and the solid support washed. The washed support is incubated with, for example, a labeled anti-antibody and incubated as before. The label is detectable and may be a radio isotope, a stable isotope, a fluorescent chemical, a luminescent chemical, a metal, an electrical charge, an enzyme, a chromatic chemical, a spatial chemical, an electron-dense molecule, or a label detectable by mass spectrometry. The amount of labeled antibody which binds to the solid support is determined and compared to the amount of labeled, non-specific antibody which remains bound in control assays. Control assays comprise assays that test biological samples which are known not to contain marker-specific antibody or another assay which provides a determination of background levels of antibody and/or a baseline internal negative control. If the amount of antibody bound is greater than a predetermined background or base level, the biological sample contains seminal vesicle-specific antibodies and the patient is diagnosed as likely to have invasive prostatic neoplasia.
Alternatively, the assay can be performed without washing and without separate incubation steps by using polyclonal or monoclonal antibodies. For example, using a competition assay, excess labeled antibody is added to antigens fixed to a solid support. This provides a measure of 100% binding. To another sample or series of samples, biological samples, such as samples of serum, are added to the incubation mixture and any decrease from 100% binding is indicative of the presence of seminal vesicle-specific antibodies in the sample.
This invention also comprises procedures and techniques to identify, isolate, and utilize markers derived from tissues other than the seminal vesicles for the detection of invasive prostatic neoplasia. Likely tissues include those tissues which surround and are in close proximity with the prostate such as the prostate capsule, the ejaculatory duct, the bladder, the vas deferens, the bulbourethral gland, the crus, the urethra, the corpus spongiosum, and the corpus cavernosum. Markers may be passively released upon tissue damage by the invading prostatic cells or actively released into new areas of the body. The non-prostate, non-seminal vesicle-derived markers may be proteins, cytokines, modified proteins, peptides, complex biochemicals, fragments of proteins or peptides, nucleic acids, or modifications or combinations thereof. As before, likely markers of prostate neoplasia may be identified in biological samples, such as tissue, blood, semen, or urine, and traced back to one or more of these tissues. Alternatively, these tissues can be fractionated and screened for likely markers and these markers used in diagnostic kits and methods utilizing procedures described herein. In addition, host reactions, both humoral and cellular, would occur against passively or actively released markers. Antibodies to these markers could also be detected in diagnostic kits and are also described herein.
The following examples are offered to illustrate embodiment of the present invention, but should not be viewed as limiting the scope of the invention.
EXAMPLES
Example 1 - Identification of Seminal Vesicle-Specific Markers
Seminal vesicle tissue is surgically removed from a human cadaver or removed by radical prostatectomy biopsy from a patient to a 100 mm tissue culture dish containing about 10 ml of cold (4° C.) hypertonic buffer (50 mM Tris-Cl, pH 7.0; 1.0 mM KCl; 1 mM PMSF; 10 mM EDTA; +/-1 mM DTT). Tissue is mechanically minced and/or dispersed by passage through a 19 gauge needle, followed by homogenization using either a cylindrical homogenizer or rotary tissue disrupter. The membrane fractions and soluble fractions of samples are separated by centrifugation. The pelleted fraction is suspended in hypotonic buffer plus 2% SDS and centrifugation is repeated. This process is diagrammatically outlined in FIG. 1. Optionally, lectin affinity chromatography may be used to enrich the soluble fractions for glycoproteins (as predictive for secretory proteins).
Semen, urine, and blood samples are collected from normal volunteers and patients with suspected or confirmed cases of prostatic carcinoma at various stages of severity. Semen ejaculate samples, preferably from normal vasectomized individuals, are mixed immediately with PMSF and EDTA in chilled phosphate buffered saline, pH 7.2 (PBS) or hypotonic buffer. These samples are separated into soluble and particulate fractions by pelleting at 10,000×g for 10 minutes. The particulate fraction may be suspended in hypotonic buffer and diluted as necessary to about 1 ug/100 ul in PBS. The soluble fraction may be concentrated using Amicon filters or diluted with PBS as necessary to about 1 ug/100 ul of liquid. Seminal vesicle fractions including the membrane fraction, the soluble fraction and the enriched fraction, and fractions of blood and semen are subjected to SDS polyacrylamide gel electrophoresis (PAGE) under reducing or non-reducing conditions, along with appropriate molecular weight markers and negative controls. SDS-PAGE gels have an extended longitudinal dimension (ca. 16") for enhanced band resolution. The resulting gel matrices are subjected to electrotransfer to a suitable membrance such as nitrocellulose.
Briefly, the electrophoresis matrix is equilibrated for about 30 minutes in transfer buffer (18.2 g Tris Base; 86.5 g glycine; 4.0 liters H 2 O; 1200 ml methanol) at room temperature. Pre-wetted nitrocellulose transfer membrane is cut to size and placed on top of the gel. Pre-wetted Whatmann 3 MM filter papers are placed on both sides of the gel-nitrocellulose slab, and the entire structure placed in an electrophoresis tank of transfer buffer. Electrophoresis is begun for 30 minutes at 100 volts, turned down to 14 volts (constant voltage) and continued overnight (about 14 hours) at 4° C. Upon completion of the transfer, the membrane is removed and assayed for transfer efficiency.
To visualize transferred proteins, membranes are placed in Ponceau S solution (0.5 g Ponceau S dissolved in 1 ml glacial acetic acid and brought to a total volume of 100 ml with H 2 O just before use) for 5 minutes at room temperature. The membranes are destained for 2 minutes in water and photographed using transmitted light through the stained nitrocellulose membrane. A photograph of a representative stained membrane of a high-resolution, 16" PAGE gel is shown in FIG. 2A. Bands observed on the membrane are isolated directly or the seminal vesicle-specific antigens further identified by probing the membranes with seminal vesicle-specific antibody created as follows. Briefly, fractions of seminal vesicle tissue, blood and/or semen, created above, are mixed with equal volumes of incomplete Freund's adjuvant and injected subcutaneously into female rabbits using a 25-gauge needle at a dose of about 400 ul per injection. The first antigen only is presented in complete Freund's adjuvant. Each animal receives from one to ten injections at various sites high on the dorsal flank between the ribs and the hip. Antigen injections are repeated approximately every two weeks for a minimum of three times using fresh seminal vesicle tissue materials.
After about four weeks from the initial injection, 5-10 ml samples of blood are collected by venipuncture from the rabbits' marginal ear vein using a 23-gauge needle. Blood flow is stopped by applying gentle pressure to the cut with sterile gauze for 10-20 seconds. Collected blood is allowed to clot for a minimum of one hour at room temperature. The clotted material is removed with sterile tweezers and any remaining solid material removed by centrifugation at 10,000×g for 10 minutes. Serum is stored in 500 ul aliquots at -80° C. until use.
Ponceau S stained membranes are completely destained by continuing to soak in water for an additional 10 minutes and placed in heat-sealable plastic bags or trays with 5 ml of blocking buffer (0.1% Tween 20 in 100 mM Tris-Cl, pH 7.5; 0.9% NaCl), for about 30 minutes at room temperature on an orbital shaker. Serum samples (including normal pre-immune rabbit serum control samples) are thawed, diluted at 1:100 to 1:10,000 in blocking buffer, and 5 ml added to the bags or trays along with fresh blocking buffer. The membranes are incubated for 30 minutes to overnight at room temperature in an orbital shaker. After incubation, the membranes are removed and washed in blocking buffer several times for about 15 minutes each with agitation. Commercially available alkaline-phosphatase conjugated anti-rabbit secondary antibody with fresh blocking buffer is added to the bags or trays which are incubated for one hour at room temperature in an orbital shaker. After incubation, the buffer is removed and the membranes treated according to the appropriate enzymatic visualization protocol.
Bands observed using seminal vesicle specific anti-serum in the blood, urine, or semen sample that are also observed in the seminal vesicle sample, but not in the negative control samples or using normal rabbit serum are considered positive and likely candidates for use in the detection of prostatic neoplasia.
Example 2 - Isolation of Seminal Vesicle-Specific Markers
Positive bands visualized by Ponceau S staining in Example 1 are directly excised from the membrane (FIG. 2B). Excised bands are ground into a powder or dissolved in DMSO using the method of Kundson (K. A. Kundson, Proteins transferred to nitrocellulose for use as immunogen, Annual-Became. 147:285, 1985), mixed with incomplete Freund's adjuvant and injected into rabbits as described in Example 1 to generate specific antisera. The first antigen only is presented in complete Freund's adjuvant.
This antisera can be used directly to identify seminal vesicle-specific markers in patient samples, such as samples of blood, urine, or semen and are analyzed by Western blot or can be used to create immunoaffinity columns. Briefly, antisera is diluted to about 20 ug/ul in PBS. Two mils of serum are dialyzed against one liter of dialysis solution (100 rnM NaHCO 3 ; 400 mM NaCl) at 4° C. for 24 hours with three solution changes. The dialyzed serum is centrifuged at 100,000×g for one hour to remove aggregates, the resulting supernatant is diluted to 5 mg/ml with dialysis solution, and the clarified serum stored at 4° C. Commercially available cyanogen bromide (CNBr) activated Sepharose is prepared according to the appropriate protocol and coupled with the antibodies of the serum. The percent coupling is determined and the antibody-coupled Sepharose stored at 4° C. in TSA buffer (10 mM Tris-C1, pH 8.0; 140 mM NaCl; 0.025% NAN 3 ) until use.
Appropriate fractions of seminal vesicle tissue or fluid, blood, or semen are prepared as before and added to columns of antiserum coupled Sepharose. The columns are washed with TSA buffer and eluted with 50 mM Tris-C1, pH 6.8. Eluted samples are confirmed to be seminal vesicle-specific using the procedure described in Example 1. Fractions collected from the immunoaffinity columns are subjected to further purification using HPLC or reverse-phase HPLC.
Example 3 - Peptide Sequencing
Proteins isolated by band excision from HPLC analysis as described in Example 2 are analyzed for amino acid composition and sequence. Band-excised purified proteins or protease digested fractions of proteins are applied to a 470A gas phase protein sequenator (Applied Biosystems, Inc.) which is connected to an ABI 120 (HPLC) PTH analyzer. Amino acid sequences determined are compared to the GENBANK DNA and NBRF protein data bases on a Macintosh IIsi personal computer using MacVector version 4.0 software to determine if the proteins have been previously identified.
Based on the sequences determined, corresponding peptide sequences are prepared. Synthetic peptides are coupled to keyhole lymphocyte hemocyanin (KLH) using commercially available kits (Pierce Chem. Co.) to facilitate anti-peptide antibody production in rabbits or mice.
Example 4 - Production of Seminal Vesicle Marker-Specific Monoclonal Antibodies
Purified and synthetic proteins and peptides are individually intraperitoneally injected into Balb/c mice in an equal volume of incomplete Freund's adjuvant at a total volume of about 250 ul per injection. Identical booster injections are given at three-week intervals. Three days after the final booster, the mouse is sacrificed and the spleen removed and placed in a 100 mm sterile culture dish with about 10 ml of RPMI 1640 medium without serum. Spleen cells are teased and torn apart using a pair of 19 gauge needles and aspirated until the cells are fully dispersed. The cell suspension is allowed to sit for three minutes for large clumps to settle and the suspended cells removed. Cells are washed twice by centrifugation at 400×g in RPMI 1640 at 37° C. in the absence of serum. P3-X63Ag8 myeloma cells of equal number are also washed twice in serum free medium at 800×g. After the final wash, the two cell pellets (myeloma and spleen cells) are combined in serum-free medium pre-warmed to 37° C. and centrifuged at 800×g for 5 minutes. All medium is carefully removed from the pellet, which is suspended in a solution of 50% PEG by slowly adding the PEG while slowly stirring the cell pellet with the end of a piper for one minute. Stirring is continued for another minute. Pre-warmed serum free medium is added to the cell suspension slowly over the next 3 minutes to a total volume of 10 mils. Cells are centrifuged for 5 minutes at 800×g and resuspended in 10 mils of medium supplemented with 10% fetal calf serum. Cell suspensions of 100 ul each are transferred into wells of a 96-well microtiter plate, incubated at 37° C. in a 5% CO 2 incubator, and the fused cells selected. After about 7-10 days cell supernatants of the fused cells are screened for antibody specific to the seminal vesicle marker of interest and the selected populations expanded. Hybridomas are picked and cultured. Monoclonal antibody is used directly or stored at -80° C. in 0.5 ml aliquots.
Example 5 - Identification and Isolation of Seminal Vesicle-Specific Marker Genes
Polyclonal and monoclonal antibodies prepared in Examples 1, 2 and 4 are used to screen human seminal vesicle-specific cDNA expression libraries for seminal vesicle-specific marker proteins. Positive bacterial colonies or bacteriophage plagues are identified by Western blotting the supernatants of individual clones with antibody preparations. Positive clones are expanded and the recombinant DNA insert restriction mapped and sequenced using dideoxynucleotide chain termination methodology. These sequences are analyzed by computer alignment to available sequences in GEN BANK as in Example 3. DNA sequences of interest are subcloned into recombinant expression vectors for large scale production of seminal vesicle-specific marker. In addition, cDNA expression libraries are screened using 32 P-radiolabeled oligonucleotides or DNA fragments as probes to either known genes, for example, semenogelin I, its three subunits, or semenogelin II, are prepared based on the peptide sequences obtained in Example 3. The oligonucleotide probes are synthesized to recognize peptide-encoding fragments enriched for the amino acid residues met, trp, phe, tyr, cys, his, gin, asn, lys, asp, and gin, in this order of priority. Such probes are capable of recognizing a minimum of 21 deoxynucleotide residues corresponding to a minimum length of seven amino acid residues.
Example 6 - Diagnostic Kits Containing Seminal Vesicle-Specific Marker.
Microtiter plates are fixed with the seminal vesicle-specific marker made recombinantly as in Example 5 or purified conventionally as in Example 2. To the fixed antigen are added samples of blood or urine obtained from both normal healthy volunteers, patients with non-prostatic forms of cancer, and patients with suspected or confirmed cases of prostatic neoplasia with varying stages of severity. The samples are incubated for one hour at room temperature in a total volume of about 100 ul, after which, all liquid is removed by flicking the plates. Plates are washed three times with PBS, after which commercially available alkaline phosphatase conjugated anti-human antibodies are added to each well and the solution treated according to the appropriate visualization protocol. If the biological samples of, for example, blood or urine, contain seminal vesicle-specific antibodies, the antisera will bind to the fixed antigen. Positive indications are determined by comparing the binding observed with samples from the prostatic neoplasia positive patients with baseline determinations made for binding observed with samples obtained from normal individuals or individuals with other forms of cancer.
Kits are also created using immuno-slot blots. Nitrocellulose membranes are placed in a slot blot apparatus and the various patient samples of serum, urine or semen, are placed individually in the slots and immobilized. Binding is detected using labeled seminal vesicle-specific marker or seminal vesicle-specific marker and a labeled secondary to detect bound marker and an appropriate visualization protocol. Alternatively, the marker protein may be bound to individual wells of the slot blot. Each well is cut with scissors to isolate immobilized antigen, immersed and incubated in patient samples, rinsed, and anti-human antibody conjugates applied to detect the complex. In addition to these methods, human antisera can be applied directly to Western blot membranes containing electrophoresed and transferred seminal vesicle components of homogenates or purified proteins. Following rinsing, anti-human antibody conjugates are applied to detect the complex.
Example 7 - Diagnostic Kits Containing Antibody Specific To Seminal Vesicle-Specific Markers
Microtiter plates are fixed with anti-seminal vesicle-specific rabbit polyclonal or murine monoclonal antibody prepared as described in Examples 2 and 4, or human monoclonal antibody. Human monoclonal antibody is created by fusing human spleen cells, which were exposed to antigen, with human or partly human myeloma cells and selecting the appropriate hybridoma cells or by cloning the antibody binding site of a non-human antibody gene into the appropriate position of a human antibody expressing cell. To the fixed seminal vesicle-specific antibodies are added samples of blood, semen, or urine obtained from normal healthy volunteers, patients with non-prostatic forms of cancer, and patients with suspected and confirmed prostatic neoplasia with varying stages of severity. The plates are incubated for one hour at room temperature in a total volume of 100 ul. After one hour, the liquids in the samples are removed by flicking the plates dry and the plates washed three times with PBS. Alkaline-phosphatase conjugated secondary antibody is added and the plates are treated according to the appropriate visualization protocol. Positive indications are determined by comparing the binding observed with the samples obtained from prostatic neoplasia patients with a baseline binding level observed in samples taken from normal healthy volunteers and patients with non-prostatic forms of cancer.
Kits are also created using slot blots as in Example 6. Nitrocellulose membranes are placed in a slot blot apparatus and the various patient serum, urine, and semen samples, placed individually in the slots and immobilized. The amount of marker protein is determined using labeled seminal vesicle-specific antibody and an appropriate visualization protocol. In addition to these methods, the human samples are resolved on SDS PAGE gels and Western blotted using rabbit polyclonal, mouse monoclonal, or human monoclonal antibodies that recognize a specific marker protein. A secondary conjugated antibody is used to visualize the complex.
Other embodiments or uses of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered exemplary only, with the true scope and spirit of the invention being indicated by the following claims. | 4y
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FIELD OF THE INVENTION
[0001] The invention relates to fluid line connections and particularly to tubing connections such as those that are frequently employed in medical treatment devices.
BACKGROUND
[0002] Tubing connections are commonly used medical treatment systems, chemical processing plants, pharmaceutical plants, laboratories, etc. A common class of connectors mate by mutually rotating parts of the connectors, by pushing them together, or both. One common type of connector is a luer connector which includes a relatively long male element which fits tightly in a channel of a female element. In 1970s luers were merely pushed together to make a connection. Later, threaded collars were added to make it harder for the luer connectors to come apart. Even though the threaded collar increases the reliability of the connection, in some applications, such as extracorporeal blood treatment systems, it is desirable to address even minute levels of risk, if possible. There is a need in the art for simple and inexpensive ways to increase the reliability of connectors for fluid-carrying vessels and particularly, this need is felt in the area of tubing systems used in medical treatment devices. In particular, it would be desirable to enhance the security of luer-type connectors without altering the familiar features of their design or usability.
SUMMARY
[0003] Various mechanisms and methods for preventing the accidental decoupling of connectors are provided. All are particularly adapted for use with luer-type connectors.
[0004] According to an embodiment, a connector protection device operates with a connector having first and second mating parts which are held together by a non-frictional engagement device. The device includes a first connector and a second connector which are configured to mate to define a continuous flow path between them. A securing element prevents the first and second connectors disconnecting by at least one non-frictional mechanism. The securing element is movable with respect to at least one of the first and second connectors to allow the first and second connectors to disconnect. A disconnection prevention member extends between the first and second connectors and is effective to prevent at least one of a movement of the securing element and a separation of the first and second connectors such that the first and second connectors are prevented from disconnecting. In one variation, the first and second connectors form a luer-type connector and the securing element includes a threaded barrel on one of the first and second connectors that engages a threading element on the other of the first and second connectors. In a variation of the latter embodiment, the disconnection prevention member prevents the barrel from rotating relative to the other of the first and second connectors.
[0005] According to another embodiment, the connector protection device prevents the disengagement of two mating connectors which have a locking component that maintains the connection between the mating connectors by non-frictional means. For example, the two connectors may be screwed together or clamped together. Clamps and screws provide a positive engagement between the mating connectors. Whereas a luer connector without a locking thread portion, such as the prior art luer connectors lacking a locking device, relied on frictional engagement between the male and female luer to maintain the connection between the male and female connector components. In the embodiment, a protector helps to ensure that the connectors do not come apart either by backing the connector element up or by preventing it from disengaging and thereby permitting the connectors from coming apart. So, for example, if the connectors are luer connectors and the locking component is a threaded barrel, the connector protection device could serve the function defined by either preventing the barrel from rotating or by preventing the male and female luers from separating if the threaded barrel fails. Thus, in the embodiment, the connection protection device is one of: (1) a device that prevents the decoupling of the connectors such that failure of the connection is either prevented or inhibited by holding the connectors together and (2) a device that locks the locking component, thereby preventing it from failing to do its job.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate exemplary embodiments of the invention, and, together with the general description given above and the detailed description given below, serve to explain the features of the invention.
[0007] FIG. 1 shows a typical luer-type inline connector.
[0008] FIGS. 2A and 2B show a flexible disconnect protector design which prevents the luer-type connector of FIG. 1 from disconnecting.
[0009] FIG. 3 shows the disconnect protector of FIGS. 2A and 2B positioned to prevent the disconnection of a luer-type connector.
[0010] FIG. 4 illustrates a step and a configuration used to remove or install the disconnect protector of FIGS. 2A and 2B on the luer-type connector.
[0011] FIG. 5 shows a position in which the disconnect protector can be placed to disconnect the luer-type connector.
[0012] FIG. 6 shows a modified luer-type connector with wings on a rotating part that engage with another disconnect protector.
[0013] FIGS. 7A through 7C show additional embodiments of disconnect protector.
[0014] FIG. 8 shows the embodiment of FIG. 7A in use with the luer-type connector of FIG. 6 .
[0015] FIGS. 9A through 9C show various disconnect protectors.
[0016] FIGS. 10A through 10C show a disconnect protector with a pivoting latch that prevents a threaded lock from rotating and, in a variation, also prevents the separation of the mating parts of the connector.
[0017] FIG. 10D shows a clip-on-type embodiment of a disconnect protector.
[0018] FIG. 11 shows a another clip-on type embodiment of a disconnect protector.
[0019] FIG. 12 shows a clam-shell embodiment of a disconnect protector.
[0020] FIG. 13 shows a portion of a medical tubing set support with an unused region that may be punched and formed to form one or more disconnect protectors.
[0021] FIGS. 14A through 14C show a disconnect protector that prevents rotation of a lock by a releasable ratchet mechanism.
[0022] FIGS. 15A and 15B show the ratchet mechanism of the embodiment of FIGS. 14A and 14B .
[0023] FIGS. 16A and 16B show an adapter that can be added to a connector that lacks an appropriately-shaped portion with an edge to engage the disconnection protection device of the embodiments of FIG. 2A , for example.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0024] Referring to FIG. 1 , a luer-type connector 100 has a male end 100 M and a female end 100 F. The male end 100 M has an internally-threaded barrel 106 that threads with bosses or threads (not shown, but see, for example, U.S. Pat. Nos. 4,452,473 to Ruschke; 4,639,019 to Mittleman; and 5,984,373 to Fitoussi, et al, which are hereby incorporated by reference as fully set forth herein) on the female end 100 F. The barrel 106 rotates relative to a male luer 104 (the conical mating portion of the connector is hidden within the barrel 106 and so is not shown, but is contiguous with the male luer 104 ) to engage the bosses or threads (again, not shown) to bring the female and male ends 100 F and 100 M together and force the male luer 104 into the female luer 110 (the conical recess that mates with the conical portion of the male luer 104 connector is hidden, partly within the barrel 106 , and so is not shown, but is contiguous with the female luer 110 ). Note that in an alternative embodiment, the threaded barrel 106 could be on the female luer 110 and thread with bosses on the male luer 104 to similar effect. Tubes 102 and 112 together with the luer-type connector 100 form a continuous channel when the male and female luers 104 and 110 are mated. Wings 108 may be provided on one or both of the male and female luers 104 and 110 .
[0025] Referring now also to FIGS. 2A , 2 B and 3 , edges 114 and 116 provide engagement portions for a disconnection protection device 130 which can be fitted over the mated luer-type connector 100 as shown in FIG. 3 . The disconnection protection device 130 , in the present embodiment, is of flexible material such as thermoplastic sheeting, steel, rubber, fiberglass or other composite, textile, or any suitable material that is resilient such that it can be bent as shown in FIG. 2B while springing back toward the relatively flat shape shown in FIG. 2A .
[0026] The disconnection protection device 130 can be moved over the luer-type connector 100 when bent as shown in FIG. 4 and when released in the position shown in FIG. 3 , engages an edge 133 of opening 132 with the edge 114 and engages an edge 135 of opening 131 with the edge 116 . Thus, in the position shown in FIG. 4 , the disconnection protection device 130 prevents the male luer 104 and female luer 110 from moving apart. As a result, even if the barrel 106 is rotated to release the bosses or threads of the female end 100 F, the male and female ends 100 M and 100 F will not come apart. The disconnection protection device 130 need not hold the male and female ends 100 M and 100 F tightly since the luer-type of connector forms a slowly-expanding channel as the male luer withdraws from of the female luer. As a result, a small amount of separation will produce a similarly small leak area and the male and female ends 100 M and 100 F must be drawn apart a considerable distance for a large leak to occur. As shown in FIG. 5 , the disconnection protection device 130 can be bent and passed over one of the tubes 112 and 102 and released so that it remains in close proximity to the luer-type connector 100 while freeing the luer-type connector 100 to be closed or opened.
[0027] Referring to FIG. 6 , a luer-type connector 200 has male a male end 200 M and a female end 200 F. The male end 200 M has an internally-threaded barrel 206 that threads with bosses or threads (again, not shown but as described above and in the documents incorporated by reference) on the female end 200 F. The barrel 206 rotates relative to a male luer 204 to engage the bosses or threads to bring the female and male ends 200 F and 200 M together and force the male luer 204 into the female luer 210 . Note that in an alternative embodiment, the threaded barrel 206 could be on the female luer 210 and thread with bosses on the male luer 204 to similar effect. Tubes 202 and 212 together with the luer-type connector 200 form a continuous channel when the male and female luers 204 and 210 are mated. As in the above embodiments, wings 208 may be provided on one or both of the male and female luers 204 and 210 .
[0028] In the embodiment of FIG. 6 , extensions 216 are provided on the barrel 206 . Also, there are four wings 208 on the female luer 210 . Referring now also to FIGS. 7A and 8 , a disconnection protection device 230 has openings 240 and 241 which receive one of the extensions 216 and one of the wings 208 , respectively. As a result, when the disconnection protection device 230 is installed as discussed with reference to the embodiments of FIGS. 1-5 , one extension 216 A and one wing 208 A fits through the openings 240 and 241 , respectively thereby inhibiting the barrel 206 from rotating relative to the female luer 210 . As a result, disconnection by unthreading the barrel internal threads from the female luer 210 bosses or threads is prevented.
[0029] Referring to FIG. 7B , instead of openings 240 and 241 , recesses 252 may be formed in a disconnection protection device 250 which is otherwise similar to that disconnection protection device 230 of FIG. 7A . The recesses 7 B may be formed, for example, in thermoplastic sheeting, by molding, such as vacuum molding. Also, in alternative configurations, extensions 216 and wings 208 could be replaced by hook-shaped extensions that catch on or both of outer edges 237 of a device similar to the disconnection protection device 230 . Also, alternatively, the disconnection protection device could have an hourglass shape as shown in FIG. 7C that necks down to create a narrow center section 284 between the openings 285 such that the extensions 216 A wings 208 A will catch the edge of the narrow center section 284 .
[0030] Referring to FIGS. 9A , 9 B, and 9 C, various alternative embodiments of disconnection protection device 271 , 273 , and 275 are shown. Disconnection protection device 271 has rounded openings 373 , which is an alternative shape for the openings. The disconnection protection device 271 also has a bridging slot 375 which allows the disconnection protection device 271 to be snapped over the luer-type connector 100 or 200 rather than sliding it over the luer-type connector 100 or 200 . Disconnection protection device 273 has slots 279 which are formed to allow them to expand to admit the luer-type connector 100 or 200 and a bridging slot 371 which allows the disconnection protection device 273 to be snapped over the luer-type connector 100 or 200 . disconnection protection device 275 has rectangular openings 277 .
[0031] Referring to FIG. 10A , a luer-type connector 300 has male a male end 300 M and a female end 300 F. The male end 300 M has an internally-threaded barrel 306 that threads with bosses or threads (again, not shown but as described above and in the documents incorporated by reference) on the female end 300 F. The barrel 306 rotates relative to a male luer 304 to engage the bosses or threads to bring the female and male ends 300 F and 300 M together and force the male luer 304 into the female luer 310 . Again, note that in an alternative embodiment, the threaded barrel 306 could be on the female luer 310 and thread with bosses on the male luer 304 to similar effect. Tubes 302 and 312 together with the luer-type connector 300 form a continuous channel when the male and female luers 304 and 310 are mated.
[0032] Referring to FIGS. 10A through 10C , attached to the female luer 310 is a pivoting latch 330 that locks the barrel 306 to prevent it from rotating. The latch 330 pivots on a hinge 337 which holds the latch on the female luer 310 . Protrusions 334 may be formed in the latch 330 to facilitated locking engagement of the barrel 305 , which may be provided with a knurled surface 336 . FIG. 10A shows the embodiment of the disconnection protection device 300 from a bottom perspective and FIG. 10B shows the same embodiment of the disconnection protection device 300 from the side. FIG. 10C shows the disconnection protection device 300 from the side with the latch 330 pivoted in a disengaged position to allow the barrel 306 to be rotated. The protrusions 334 may be shaped to cause the latch 330 to snap over the barrel 306 , thereby holding the latch 330 in position as shown in FIGS. 10A and 10B . When engaged, the latch 330 prevents the barrel 306 from rotating relative to the female luer 310 thereby preventing the internal threads (not shown) of the barrel 306 from uncoupling from the bosses or threads (also not shown) of the female luer 310 .
[0033] FIG. 10D shows a snap-on variation of a disconnection protection device 350 which snaps to both a male luer 354 barrel 356 and a female luer 360 which has a knurled surface 367 . Protrusions 363 and 365 on a clip element 380 engage the knurled surface of the barrel 356 and the knurled surface 367 of the female luer 360 . This prevents the barrel 356 from rotating relative to the female luer 360 thereby preventing disconnection by preventing the internal threads (not shown) of the barrel 356 from uncoupling from the bosses or threads (also not shown) of the female luer 360 . The disconnection protection device 350 has narrow openings 362 and 369 that engage ends of the male luer 354 and the female luer 360 to prevent the male and female ends 350 M and 350 F from uncoupling even in the event the barrel 356 rotates or the threads are not engaged.
[0034] FIG. 11 shows another clip-on variation of a disconnection protection device 400 which has slots 408 in extensions 402 and 404 which engage the ends (for example, 214 and 216 ) to prevent the luer-type connector 100 , 200 from decoupling. FIG. 12 shows a clamshell embodiment of a disconnection protection device 420 in which may be closed around the luer-type connector 100 , 200 or similar connector. A curved leaf spring 422 closes the clamshell disconnection protection device 420 such that the covers 422 and 434 fully enclose the luer-type connector and such that the edges of the male and female luers (for example, 214 and 216 ) are held back while permitting the tubing to pass through openings 426 and 428 . FIG. 13 shows a cartridge panel 450 which holds a tubing set which may include one or more luer-type connectors. The cartridge panel 450 may be made of sheet material whose properties are suitable for some of the disconnection protection devices described herein. The cartridge panel may have various cutouts and other shapes formed in it in various operations such as punching and vacuum-forming. An unused area is shown at 452 and the outline of a disconnection protection device 454 is shown. In the embodiment, the disconnection protection device 454 is formed and cut from the cartridge panel 450 during its manufacture. The cartridge panel is described in U.S. Pat. No. 6,579,253 to Burbank, et al, hereby incorporated by reference as if fully set forth herein.
[0035] Referring to FIGS. 14A and 14B , a luer-type connector 500 has male a male end 500 M and a female end 500 F. The male end 500 M has an internally-threaded barrel 506 that threads with bosses or threads (again, not shown but as described above and in the documents incorporated by reference) on the female end 500 F. The barrel 506 rotates relative to a male luer 504 to engage the bosses or threads to bring the female and male ends 500 F and 500 M together and force the male luer 504 into the female luer 510 . Again, note that in an alternative embodiment, the threaded barrel 506 could be on the female luer 510 and thread with bosses on the male luer 504 to similar effect. Tubes 502 and 512 together with the luer-type connector 300 form a continuous channel when the male and female luers 304 and 310 are mated. FIG. 14B , which shows the luer-type connector 500 uncoupled, shows a tapered end 534 of the male luer 504 and an end 536 of the female luer 510 which has the mating conical recess that receives the male luer 504 tapered end 534 .
[0036] The luer-type connector 500 has a disconnection protection device integrated in the design of the connector. On the female luer 510 , a ratchet barrel 508 has a ratchet 526 with teeth 528 which is urged toward a circular rack 538 by a living hinge 565 . The teeth of both the rack 538 and ratchet 526 are shaped to cause them to engage such that the barrel 506 cannot turn relative to the ratchet 526 of the female luer 510 , thereby preventing unthreading. This is similar to the well-known structure of cable ties, typically made of nylon. As shown in FIG. 14C , the living hinge 565 allows pressure to be applied to the top of the ratchet 526 by squeezing or pinching the ratchet barrel 508 . This causes the ratchet surface 528 to withdraw from the circular rack 538 disengaging the barrel 506 allowing the luer-type connector 500 to be uncoupled. In this embodiment, as in the others, the ratchet could be provided on the male end and the rack on the female end of the luer-type connector with similar effect. This is true in all of the above embodiments, whether specifically indicated with respect to the embodiment or not.
[0037] In an embodiment, the connector protection device prevents the disengagement of two mating connectors which have a locking component that maintains the connection between the mating connectors by non-frictional means. For example, the two connectors may be screwed together or clamped together. Clamps and screws provide a positive engagement between the mating connectors. Whereas a luer connector without a locking thread portion, such as the prior art luer connectors lacking a locking device, relied on frictional engagement between the male and female luer to maintain the connection between the male and female connector components. In the embodiment, a protector helps to ensure that the connectors do not come apart either by backing the connector element up or by preventing it from disengaging and thereby permitting the connectors from coming apart. So, for example, if the connectors are luer connectors and the locking component is a threaded barrel, the connector protection device could serve the function defined by either preventing the barrel from rotating or by preventing the male and female luers from separating if the threaded barrel fails. Thus, in the embodiment, the connection protection device is one or both of: (1) a device that prevents the decoupling of the connectors such that failure of the connection is either prevented or inhibited by holding the connectors together and (2) a device that locks the locking component, thereby preventing it from failing to do its job.
[0038] In the embodiment of FIGS. 1 through 5 , the locking element is the barrel 106 and the connector protection element is the disconnection protection device 130 . The disconnection protection device 130 falls into the first category; that is, it prevents the decoupling of the connectors (male luer 104 and female luer 110 ) such that failure of the connection is either prevented or inhibited by holding the connectors together embodiment.
[0039] In the embodiments of FIGS. 9A through 9C , the disconnection protection devices 271 , 273 , and 275 perform the same role. In the embodiments of FIGS. 6 through 8 , the disconnection protection devices 230 and 250 also perform the same role of preventing the decoupling of the connectors (male luer 204 and female luer 210 ) such that failure of the connection is either prevented or inhibited by holding the connectors together but they also serve the second role of locking the locking component (i.e., the barrel 206 ), thereby preventing the barrel 216 from failing to do its job.
[0040] In the example of the embodiment of FIGS. 6 through 8 , the barrel 206 is prevented from rotating relative to the female luer 210 by causing the extension 216 and the wing of the female luer 210 from engaging a common element, namely the disconnection protection device 230 . This in turn prevents relative rotation of the female luer 210 and the barrel 206 thereby preventing disengagement of the barrel threads from the female luer bosses or threads.
[0041] In the embodiment of FIGS. 10A through 10C , the locking element is the barrel 306 and the connector protection element is the latch 330 . The disconnection protection device 330 falls into the second category; that is, it locks the locking component (the barrel 306 ), thereby preventing it from failing to do its job of holding the threaded elements in continuous engagement to keep the male and female luers 304 and 310 mated. The embodiment of FIG. 10D is similar to the embodiment of FIG. 10A in that the locking element, the barrel 356 is prevented from rotating. But in this case, the disconnection protection device 352 also prevents the separation of the male and female luers 354 and 360 . Thus, the disconnection protection device 350 falls into both categories 1 and 2 .
[0042] In the disconnection protection device 500 of FIGS. 14A through 15B , the locking element is the barrel 506 and the connection protection element is the ratchet 526 . The disconnection protection device 500 thus fits in category 2 because it prevents the barrel 506 from disengaging with the female luer 510 .
[0043] In an embodiment of the invention, the connectors are luer connectors. In another, or a refinement of any of the foregoing embodiments, the connectors are used to secure a line of a medical treatment device. In yet another, or a refinement of any of the foregoing embodiments, the connectors connect blood-conveying lines of a medical treatment device. In another, or a refinement of any of the foregoing embodiments, the locking element includes a ratchet. In a further refinement, it includes rack that is engageable with the ratchet. In yet another, or a refinement of any of the foregoing embodiments, the connectors are male and female luers and the locking element includes a threaded barrel on either the male or female luer that engages on a mating portion of the other of the male and female luer.
[0044] FIGS. 16A and 16B show an adapter that can be added to connector components that do not have an edge that can securely engage the disconnection protection device of FIG. 2A , for example. A connector 614 , in this case a female luer which is secured to a catheter 640 has tabs 616 that engage threads of standard locking male luer connectors. A connector adapter 642 has a male luer with a recess 658 that has threads 618 to engage the tabs 616 in precisely the manner of a standard locking male luer connector. Integrally formed in the connector adapter 642 is a connector 630 , that replicates the original connector 614 , in this case, a female luer. When threaded onto the original connector 614 , the connector adapter defines a continuous channel from the connector 630 to the original connector 614 . The connector adapter 642 is additionally fastened to the connector 614 by a flexible band that is received in recesses 650 such that it wraps tightly to the diameter of the catheter 640 . Thus, the connector 614 is held in the recess 658 such that even if the it disengages from the threads 618 , it cannot withdraw from the connector adapter 642 .
[0045] The connector adapter 642 provides a flange 640 that can engage the disconnect protection device 624 . In the example shown in FIG. 16B , a male luer 604 with a threaded barrel 606 is connected to the female luer 630 of the connector adapter 642 . The disconnection protection device 630 is engages the flange 640 and the male luer 604 edge 614 thereby preventing the disconnection of the catheter 640 from a fluid line 622 .
[0046] In any of the above embodiments, the type of connector could be luer-type connector or any other connector which rely on mutually rotatable parts on the connecting elements or which slide apart to disconnect or both. Also, although inline connectors are shown for purposes of illustration, the disconnect protection features shown can be applied to other types of connectors such as connectors forming parts of junctions, other components such as valves or filters, and others.
[0047] While the present invention has been disclosed with reference to certain embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the present invention, as defined in the appended claims. Accordingly, it is intended that the present invention not be limited to the described embodiments, but that it has the full scope defined by the language of the following claims, and equivalents thereof. | 4y
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This is a division of application Ser. No. 08/320,705, filed on Oct. 7, 1994, now U.S. Pat. No. 5,449,795, which is a division of application Ser. No. 08/070,074 filed on Jun. 1, 1993, now U.S. Pat. No. 5,414,049, issued May 9, 1995.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to medical implants formed of a polymeric material such as ultra-high molecular weight polyethylene, with superior oxidation resistance upon irradiation and a method for making the same.
2. Description of the Prior Art
Various polymer systems have been used for the preparation of artificial prostheses for biomedical use, particularly orthopedic applications. Among them, ultra-high molecular weight polyethylene is widely used for articulation surfaces in artificial knee and hip replacements. Ultra-high molecular weight polyethylene (UHMWPE) has been defined as those linear polyethylenes which have a relative viscosity of 2.3 or greater at a solution concentration of 0.05% at 135° C. in decahydronaphthalene. The nominal weight--average molecular weight is at least 400,000 and up to 10,000,000 and usually from three to six million. The manufacturing process begins with the polymer being supplied as fine powder which is consolidated into various forms, such as rods and slabs, using ram extrusion or compression molding. Afterwards, the consolidated rods or slabs are machined into the final shape of the orthopedic implant components. Alternatively, the component can be produced by compression molding of the UHMWPE resin powder.
All components must then go through a sterilization procedure prior to use, but usually after being packaged. There exists several sterilization methods which can be utilized for medical applications, such as the use of ethylene oxide, heat, or radiation. However, applying heat to a packaged polymeric medical product can destroy either the integrity of the packaging material (particularly the seal, which prevents bacteria from going into the package after the sterilization step) or the product itself.
Because ethylene oxide may adversely impact environmental and employee safety, gamma ray, x-ray or electron beam radiation has been utilized as a preferred means of sterilization. These types of radiation use a high energy beam to kill bacteria, viruses, or other microbial species contained in the packaged medical products, achieving the goal of product sterility.
However, it has been recognized that regardless of the radiation type, the high energy beam causes generation of free radicals in polymers during radiation. It has also been recognized that the amount of free radicals generated is dependent upon the radiation dose received by the polymers and that the distribution of free radicals in the polymeric implant depends upon the geometry of the component, the type of polymer, the dose rate, and the type of radiation beam. The generation of free radicals can be described by the following reaction (which uses polyolefin and gamma ray irradiation for illustration): ##STR1##
Depending whether or not oxygen is present, primary free radicals r• will react with oxygen and the polymer according to the following reactions as described in "Radiation Effects on Polymers", edited by Roger L. Clough and Shalaby W. Shalaby, published by American Chemical Society, Washington, D.C., 1991. ##STR2##
In radiation in air, primary free radicals r. will react with oxygen to form peroxyl free radicals rO 2 ., which then react with polyolefin (such as UHMWPE) to start the oxidative chain scission reactions (reactions 2 through 6). Through these reactions, material properties of the plastic, such as molecular weight, tensile, and wear properties, are degraded.
Recently, it was found that the hydroperoxides (rOOH and POOH) formed in reactions 3 and 5 will slowly break down as shown in reaction 7 to initiate post-radiation degradation. Reactions 8 and 9 represent termination steps of free radicals to form ester or carbon-carbon cross-links. Depending on the type of polymer, the extent of reaction 8 and 9 in relation to reactions 2 through 7 may vary. For irradiated UHMWPE, a value of 0.3 for the ratio of chain scission to cross-linking has been obtained, indicating that even though cross-linking is a dominant mechanism, a significant amount of chain scission occurs in irradiated polyethylene.
By applying radiation in an inert atmosphere, since there is no oxidant present, the primary free radicals r• or secondary free radicals P• can only react with other neighboring free radicals to form carbon-carbon cross-links, according to reactions 10 through 12 below. If all the free radicals react through reactions 10 through 12, there will be no chain scission and there will be no molecular weight degradation. Furthermore, the extent of cross-linking is increased over the original polymer prior to irradiation. On the other hand, if not all the free radicals formed are combined through reactions 1 0, 11 and 12, then some free radicals will remain in the plastic component. ##STR3##
It is recognized that the fewer the free radicals, the better the polymer retains its physical properties over time. The greater the number of free radicals, the greater the degree of molecular weight and polymer property degradation will occur. Applicant has discovered that the extent of completion of free radical cross-linking reactions is dependent on the reaction rates and the time period given for reaction to occur.
Several prior art patents attempt to provide methods which enhance UHMWPE physical properties. European Patent Application 0 177 522 B1 discloses UHMWPE powders being heated and compressed into a homogeneously melted crystallized morphology with no grain memory of the UHMWPE powder particles and with enhanced modulus and strength. U.S. Pat. No. 5,037,928 discloses a prescribed heating and cooling process for preparing a UHMWPE exhibiting a combination of properties including a creep resistance of less than 1% (under exposure to a temperature of 23° C. and a relative humidity of 50% for 24 hours under a compression of 1000 psi) without sacrificing tensile and flexural properties. U.K. Patent Application GB 2 180 815 A discloses a packaging method where a medical device which is sealed in a sterile bag, after radiation/sterilization, is hermetically sealed in a wrapping member of oxygen-impermeable material together with a deoxidizing agent for prevention of post-irradiation oxidation.
U.S. Pat. No. 5,153,039 relates to a high density polyethylene article with oxygen barrier properties. U.S. Pat. No. 5,160,464 relates to a vacuum polymer irradiation process.
SUMMARY OF THE INVENTION
The present invention relates to a method for providing a polymeric material, such as UHMWPE, with superior oxidation resistance upon irradiation. For the purpose of illustration, UHMWPE will be used as an example to describe the invention. However, all the theories and processes described hereafter should also apply to other polymeric materials such as polypropylene, high density polyethylene, polyester, nylon, polyurethane and poly(methylmethacrylate) unless otherwise stated.
As stated above, while UHMWPE polymer is very stable and has very good resistance to aggressive media except for strong oxidizing acids. Upon sterilization radiation, free radicals are formed which cause UHMWPE to become activated for chemical reactions and physical changes. Possible chemical reactions include reacting with oxygen, water, body fluids, and other chemical compounds while physical changes include density, crystallinity, color, and other physical properties. In the present invention a new sterilization radiation process greatly reduces the adverse effects caused by a conventional radiation process. Furthermore, this new sterilization process does not employ stabilizers, antioxidants, or any other chemical compounds which may have potential adverse effects in biomedical or orthopedic applications.
In the sterilization process of the present invention, a polymeric orthopedic implant component to be sterilized by radiation does not contain oxidants, such as oxygen or water (or moisture), or free radicals. This may be accomplished by obtaining a raw material for the implant manufactured under a special process as described herein and forming a part of the invention.
The finished polymeric orthopedic component is then sealed in an oxidant-free atmosphere. This oxidant-free atmosphere is maintained during radiation. The radiated polymeric component is then subjected to a heat treatment to cross-rink all the free radicals within themselves. During this treatment, the condition of oxidant-free atmosphere is maintained. The irradiated, heat treated plastic component is now ready to use. Exposure to oxygen or moisture will not cause oxidation. The oxidation resistance to any oxidizing agent is similar to that of the unirradiated virgin polymer.
It is therefore an object of the invention to provide a polymeric orthopedic implant having superior oxidation resistance after irradiation.
It is still another object of the invention to provide a method for manufacturing such an implant from the resin powder thereof through the final sterilization step so that the implant may thereafter be exposed to air without degradation due to oxidation.
These and other objects are achieved by a method for producing a polymeric medical implant including the steps of placing the polymeric resin in a sealed container and removing a substantial portion of the oxygen from the container. After a predetermined time, the container is repressurized with an inert gas such as nitrogen, argon, helium or neon. The resin is thereafter transferred to a forming device which normally melts and forms the resin in an oxygen reduced atmosphere to produce a polymeric raw material. The polymeric raw material, such as UHMWPE is then machined to an implant such as a tibial tray or a liner for an acetabular cup. The finished part is then sealed into a package in an oxygen reduced atmosphere. The package is of an air-tight nature to prevent oxygen or moisture from entering after the package is sealed. The then packaged implant is radiation sterilized and then heat treated for the predetermined time and temperature sufficient to form cross-links between free radicals of the neighboring polymeric chains. This prevents further oxidation once the implant is removed from the package.
In general, the implant is heated for at least 48 hours at a temperature of about 37° C. to about 70° C. and preferably for 144 hours at 50° C.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the preferred method, a raw polymeric material such as UHMWPE is obtained by, for example, ram extrusion, compression molding, or other forming processes. These methods use virgin polymer powder as a starting material. However, virgin polymer resin powder may contain air or moisture, which may exist in the resin micro-structure or simply deposited on the resin surfaces. If air or moisture is not removed from resin powder prior to the forming process, it can be trapped in the plastic matrix after forming and can not escape. This is true even with the use of vacuum or gas flushing techniques. During the sterilization radiation process, the trapped air or moisture or both will react with free radicals generated in the plastic to cause oxidation. The trapped moisture can also absorb radiation energy and dissociate into oxygen and hydroxyl free radicals which will also react with the plastic to cause oxidation. Therefore, by removing air and moisture prior to the forming process, oxidation during sterilization radiation can be avoided.
The preferred method for eliminating air and moisture is to apply a vacuum of less than 3" of mercury (76 torr) to the polymer resin for a prescribed time to reduce the levels of air and moisture to a minimal or acceptable value. The level for oxygen is preferably 0.5% (volume by volume and no more than 1%). The moisture level is preferably 10% of relative humidity (and no more than 20% relative humidity). Then sufficient amounts of deoxidizing agents, such as oxygen absorbents and moisture desiccants, are placed together with the polymer resin in a sealed container to reduce the levels of air and moisture to the minimal or acceptable value. An example of an oxygen absorbent is AGELESS® which is an iron oxide compound and commercially available from Cryovac Division, W. R. Grace & Co., Duncan, S.C.. An example of moisture desiccant is silica gel which is commercially available. These materials are placed with the resin in the sealed container for approximately 10 hours. Alternately, or in combination, an inert gas, such as nitrogen, argon, helium or neon is used to flush the container, holding the polymer resin powder, until the levels of air and moisture are reduced to the accepted value. Of course, any combination of the above methods can also be used.
In order to ensure a raw material for an orthopedic implant with no oxygen, not only must the UHMWPE resin powder be free of air and moisture, but the entire forming operation of, for example, ram extrusion, compression molding, or other forming process should be carried out in an inert or low oxygen atmosphere as well. During the forming process, due to high temperature and high pressure applied in the process, UHMWPE polymer chains may be broken to generate free radicals and cross-links. While cross-links generated in the forming process have no adverse effects on material properties, the free radicals produced, as described above, can react with air or other oxidants. Therefore, it is important to maintain the inert atmosphere during the forming process to minimize oxidation.
Any free radicals generated should be eliminated as soon as the forming process is completed by annealing. If the formed UHMWPE contains free radicals and is exposed to air or other oxidants after the forming process, oxidation will occur. The polymer should be annealed at an elevated temperature in an inert atmosphere for a prescribed time. This is because the rate of free radical reactions (reactions 10 through 12) increase with increasing temperature, according to the following general expressions: ##EQU1##
Compared to room temperature, an elevated temperature not only increases the reaction rate constants, k 1 and k 2 , but also helps free radicals r. and P. to migrate in the plastic matrix to meet other neighboring free radicals for cross-linking reactions. In general, the desired elevated temperature is between the room temperature and the melting point of the polymer. For UHMWPE, this temperature range is between about 25° C. and about 140° C. However, the preferred annealing temperature range is from about 37° C. to about 135° C. The preferred time and temperature is 130° C. for 20 hours with the minimum annealing time being about 4 hours (requiring a temperature at the high end of the range). It is to be noted that the higher the temperature used, the shorter the time period needed to combine free radicals. Additionally, due to the high viscosity of an UHMWPE melt, the formed UHMWPE often contains residual (internal) stress caused by incomplete relaxation during the cooling process, which is the last step of the forming process. The annealing process described herein will also help to eliminate or reduce the residual stress. A residual stress contained in a plastic matrix can cause dimensional instability and is in general undesirable.
In applications such as for orthopedic implants, the formed UHMWPE is further machined into desired shapes. In general, the machining is done at room temperature and no damage to the plastic will occur. However, certain machine tools, when operated at a high speed, may generate local heat and cause thermal breakdown of UHMWPE polymer chains. In this case, the above described annealing process may be employed to eliminate any newly formed free radicals prior to packaging.
After machining, the polymeric component is packaged in an air tight package in an oxidant-free atmosphere. Thus, all air and moisture must be removed from the package prior to the sealing step. Machines to accomplish this are commercially available, such as from Orics Industries Inc., College Point, N.Y., which flush the package with a chosen inert gas, vacuum the container, flush the container for the second time, and then heat seal the container with a lid. In general, less than 0.5% (volume by volume) oxygen concentration can be obtained consistently. An example of a suitable oxidant impermeable (air tight) packaging material is polyethylene terephthalate (PET). Other examples of oxidant impermeable packaging material is poly(ethylene vinyl alcohol) and aluminum foil, whose oxygen and water vapor transmission rates are essentially zero. All these materials are commercially available. Several other suitable commercial packaging materials utilize a layer structure to form a composite material with superior oxygen and moisture barrier properties. An example of this type is a layered composite comprised of poly-propylene/poly(ethylene vinyl alcohol)/polypropylene.
In general, the sterilization radiation step for the packaged implant may take a few hours to complete. As described above, it is imperative that during this time period, the transmission of oxidants, such as oxygen and moisture, into the package be kept to a minimal or at an acceptable value to avoid oxidation.
Following sterilization radiation, a heat treatment step should be performed in an inert atmosphere and at an elevated temperature to cause free radicals to form cross-links without oxidation. If proper packaging materials and processes are used and oxidant transmission rates are minimal, then the oxidant-free atmosphere can be maintained in the package and a regular oven with air circulation can be used for heat treatment after sterilization. To absolutely ensure that no oxidants leak into the package, the oven may be operated under a vacuum or purged with an inert gas. In general, if a higher temperature is used, a shorter time period is required to achieve a prescribed level of oxidation resistance and cross-linking. In many cases, the relationship between the reaction temperature and the reaction rate follows the well-known Arrhennius equation:
k.sub.1 or k.sub.2 =A * exp (ΔH/T) (14)
where
k 1 and k 2 are reaction rate constants from reactions 13 and 14
A is a reaction dependent constant
ΔH is activation energy of reaction
T is absolute temperature (K)
However, the temperature should not exceed the distortion temperature of either the packaging material or the plastic components. For UHMWPE, the temperature range is between about 25° C. and about 140° C. However, considering the distortion of the packaging material, the preferred temperature is 37° C. to 70° C.
It is very important to ensure that the number of free radicals has been reduced to a minimal or an accepted level by the heat treatment. This is because the presence of an oxidant causes not only the oxidation of pre-existing free radicals, but also the formation of new free radicals via reactions 2 through 7. When the number of free radicals grows, the extent of oxidation and the oxidation rate will increase according to the following equations: ##EQU2##
Where free radicals r. and P. can grow in number in the presence of oxidants and in turn increase the oxidation rates. It is also to be noted that the oxidation reaction rate constants k 3 and k 4 increase with increasing temperature, similar to k 1 and k 2 . Therefore, to determine if a certain level of residual free radicals is acceptable or not, it is required to evaluate specific material properties after the plastic sample is stored or aged at the application temperature for a time period which is equal to or longer than the time period intended for the application of the plastic component. An alternative to the method to assess the aging effect is to raise the aging temperature of the plastic sample for a shorter time period. This will increase the reaction rate constants k 3 and k 4 significantly and shorten the aging time. It has been found that an acceptable level of residual free radicals is 1.0×10 17 /g for UHMWPE use for orthopedic implants.
After heat treatment, the irradiated packaged plastic component is now ready to use. The package can be opened and exposed to air or moisture without causing oxidation. The oxidation resistance of the sterilized plastic component to other oxidants is similar to that of the virgin, unirradiated polymer.
Sample Preparation
A surgical grade UHMWPE rod produced by ram extrusion was machined into samples of desirable shapes. Four sets of samples were prepared using these machined samples by the following methods:
Method A: an UHMWPE sample as machined and unirradiated
Method B: An UHMWPE sample was heat sealed in a glycol-modified polyethylene terephthalate (PETG, made by Eastman Plastics, Inc., Kingsport, Tenn.) blister in air with an aluminum lid of 0.1 mm in thickness. The sealed blister containing the UHMWPE sheet was sterilized by irradiation of gamma-rays in a dose of 2.5 Mrad. The package was then opened and exposed to room air.
Method C: An UHMWPE sample was placed in a PETG blister and heat sealed in dry nitrogen with an aluminum lid of 0.1 mm in thickness by the Orics Vacuum Gas Flush Heat Seal Machine (Model SLS-VGF-100M for modified atmosphere packaging, made by Orics Industries Inc., College Point, N.Y.) which went through the following cycles:
i) nitrogen gas (moisture-free) flush for five seconds
ii) vacuum to a pressure of equal to or below 3 inches of mercury
iii) nitrogen gas flush (moisture-free) for five seconds
iv) heat seal
The oxygen concentration in the sealed blister was measured by a Mocon Oxygen Analyzer to be 0.325% (volume by volume). The sealed blister containing the UHMWPE sample was sterilized by irradiation of gamma-rays in a dose of 2.5 Mrad. The oxygen concentration in the sealed blister after sterilization radiation was measured to be 0.350%. The package was then opened and exposed to room air.
Method D: Same as Method C, except that after gamma-ray irradiation, the sealed blister containing the UHMWPE sample was heat treated at 50° C. for 144 hours in an oven, then transferred from the oven to room temperature for cooling. After the package was cooled to room temperature, the oxygen concentration was measured by a Mocon Oxygen Analyzer to be 0.360%. The package was then opened and exposed to room air.
Samples prepared by the above methods were used in the following examples for evaluation.
EXAMPLE 1:
Two sets of 1-mm-thick UHMWPE sheets prepared by Methods A through D above were oven aged in air at 80° C. for 11 and 23 days respectively. After these sheets were cooled in room temperature, a thin film specimen of about 100 microns in thickness was cut from each of the 1-mm-thick aged UHMWPE sheets and placed in an IR window for a standard FTIR (A Nicolet 710 FTIR system was used) transmission run. A total of 32 spectra (scans) were collected and averaged. To determine the extent of oxidation, the IR absorption peaks in the frequency range of between 1660 and 1800 cm -1 , corresponding to carbonyl (C-O) functional groups, were integrated for the peak area. The peak area is proportional to the amount of oxidized UHMWPE in the specimen. To correct for difference in specimen thickness, the integrated peak area was then normalized to the specimen thickness, by dividing by the area of the 1463 cm -1 (methyl) peak which is proportional to the specimen thickness. The obtained ratio was defined as oxidation index. A third set of 1-mm-thick UHMWPE sheets prepared by methods A through D, but without oven aging, were also evaluated by the same FTIR method for comparison. Oxidation indices obtained are shown in Table 1:
TABLE 1______________________________________Sample Oxidation Index______________________________________Method A / not oven aged ca. 0.Method A / 11 day oven aging ca. 0.Method A / 23 day oven aging ca. 0.Method B / not oven aged 0.02Method B / 11 day oven aging 0.06Method B / 23 day oven aging 0.11Method C / not oven aged 0.01Method C / 11 day oven aging 0.04Method C / 23 day oven aging 0.08Method D / not oven aged 0.01Method D / 11 day oven aging 0.01Method D / 23 day oven aging 0.01______________________________________
From Table 1 results, it can be seen that the unirradiated UHMWPE sample (Method A) was free of oxidation (below the FTIR detectable level), even after 23 days of oven aging in air at 80° C. On the other hand, the UHMWPE sample irradiated in air (Method B) showed considerable oxidation and the extent of oxidation (as indicated by the oxidation index) increased with increasing aging time. After 23 days of oven aging, the oxidation index reached 0.11. For the UHMWPE sample irradiated in nitrogen (Method C), the initial oxidation index before oven aging was 0.01 which was not significant. However, during the oven aging, the oxidation index increased to 0.04 for 11 days and 0.08 for 23 days respectively. The results indicate that while irradiation in an inert atmosphere is an improvement over oxidation in air, the irradiated plastic component will oxidize further over time once it is exposed to air or other oxidants. In contrast, the UHMWPE sample irradiated in nitrogen followed by heat treatment at 50° C. for 144 hours (Method D), showed an initial oxidation index of only 0.01 which did not increase after 11 or 23 days of oven aging, indicating that this sample has superior oxidation resistance than the samples prepared by Method B or C.
EXAMPLE 2:
Two sets of 1-mm-thick UHMWPE sheets prepared by Methods B through D cited in the Sample Preparation were oven aged in air at 80° C. for 11 and 23 days respectively. After these sheets were cooled in room temperature, six tensile specimens with a dumbbell shape according to ASTM D638 (Type IV) were cut from each of the 1-mm-thick aged UHMWPE sheets. A standard tensile test was performed for each specimens at a speed of 2 inches/min. Another set of 1-mm-thick UHMWPE sheets prepared by Methods B through D cited in the Sample Preparation, but without oven aging, were also evaluated by the same tensile test method for comparison. Tensile breaking strength results (average of six tests for each condition) are shown in Table 2:
TABLE 2______________________________________Sample Tensile Breaking Strength, psi______________________________________Method B / not oven aged 6510Method B / 11 day oven aging 5227Method B / 23 day oven aging 3192Method C / not oven aged 6875Method C / 11 day oven aging 6400Method C / 23 day oven aging 6004Method D / not oven aged 6941Method D / 11 day oven aging 7113Method D / 23 day oven aging 6904______________________________________
From Table 2, tensile breaking strength shows the most deterioration for the sample irradiated in air (Method B). The sample irradiated in nitrogen (Method C) shows some improvement over the sample prepared by Method B. However, the decrease in tensile breaking strength upon oven aging still occurs. In contrast, the sample irradiated in nitrogen followed by heat treatment (50° C. for 144 hours, Method D), shows no change in tensile breaking strength, indicating a superior oxidation resistance.
EXAMPLE 3:
Two sets of 1-mm-thick UHMWPE sheets prepared by Methods B and Method D cited in the Sample Preparation were oven aged in air at 80° C. for 11 and 23 days respectively. After these sheets were cooled in room temperature, samples cut from sheets were characterized by a high temperature gel permeation chromatograph (GPC) column for molecular weight distribution. The samples were dissolved in hot trichlorobenzene (TCB). They were then run in the aforementioned solvent at 1.2 ml/min. using a Jordi Gel Mixed Bed Column, 50 cm×10.0 mm ID., at a column oven temperature of 145° C. on the Waters 150C Chromatograph. The injection size was 250 uL of a 0.1% solution. An antioxidant (N-phenyl-2-naphthylamine) was added to all high temperature GPC samples to prevent polymer deterioration.
Prior to sample runs, the column was calibrated using narrow MW polystyrene standards. Since the samples were only partially soluble in the solvent due to cross-linking, the so-determined molecular weight distribution was for the soluble portion only. To determine the extent of cross-linking (solubility), a two hundred milligram sample cut from sheets were dissolved in 100 cc of 1,2,4-trichlorobenzene. Each sample was then heated to approximately 170° C. with N-phenyl-2-naphthylamine antioxidant added for 6 hours. The samples were then hot filtered at approximately 170° C. using separate preweighed high temperature filters for each sample.
After filtration, the filters were cooled to room temperature and washed individually with dichloromethane. They were then placed in a convection oven at 105° C. for 6 hours to dry and then reweighed. The weight fraction of the undissolved (cross-linked) portion was then determined based upon the initial weight of 200 mg. To determine the low molecular weight fraction present in each sample, the weight fraction of molecular weight below 10 5 in the soluble portion, determined by GPC, was multiplied by the percent solubility to give weight percent of low molecular weight fraction in each sample. Results are shown in Table 3:
TABLE 3______________________________________ Weight Percent of Soluble Percent Weight Percent of Portion Solubility Entire SampleSample Below 10.sup.5 In Solvent Below 10.sup.5______________________________________Method B /without 28.0 98.2 27.5oven agingMethod B /11 day 36.2 100.0 36.2oven agingMethod B /23 day 48.1 100.0 48.1oven agingMethod D /without 22.7 80.9 18.4oven agingMethod D /11 day 20.5 73.6 15.1oven agingMethod D /23 day 24.2 74.7 18.1oven aging______________________________________
From Table 3, it can be seen that the sample made by Method D contains more cross-linking (i.e. less soluble) than one made by Method B. Upon oven aging, the low molecular weight fraction (defined as below 10 5 ) in the sample made by Method B increases from 0.275 to 0.481 while that of the sample made by Method D remains virtually unchanged at about 0.18 after 23 days of oven aging. The increase in low molecular weight fraction was due to chain scission caused by oxidative reactions. The results indicate that the process of method D can produce an irradiated polymer with a superior oxidation resistance.
EXAMPLE 4:
UHMWPE samples of 0.5 inch cubes prepared by Methods B and Method D cited in the Sample Preparation were evaluated for deformation under load (creep resistance). Testing procedures according to ASTM D 621 (A) (24hr/23° C./1000 psi/90 min recovery) were used. Results are summarized in Table 4:
TABLE 4______________________________________ Deformation underSample Load, %______________________________________Method B 0.80Method D 0.60______________________________________
From Table 4, it is concluded that the sample prepared by Method D, the invention, possesses a superior creep resistance (0.6%) to one prepared by Method B (0.8%).
EXAMPLE 5:
Two 1-mm-thick UHMWPE samples were annealed in a oven filled with air and dry nitrogen (oxygen concentration is below 0.2%) respectively at 130° C. for 20 hours in order to remove residual stress on the samples. After the sheets were cooled to room temperature in the oven, they were removed from the oven and cut into dumbbell shaped tensile specimens (ASTM D 638, Type V) for evaluation. A standard tensile test according to ASTM D 638 was performed at a speed of 2 inches/min for each of six specimens annealed in air and in dry nitrogen respectiveIy. Results are shown in Table 5:
TABLE 5______________________________________ Toughness,Sample EAB, % TYS, psi TBS, psi lbs-in/in.sup.3______________________________________Air annealed 414 3547 6257 10,210Nitrogen 485 3517 8917 18,960annealed______________________________________ Note: EAB elongation at break TYS tensile yield strength TBS Tensile breaking strength
From the above table, it is seen that the sample annealed in nitrogen exhibits a higher elongation at break, a higher tensile breaking strength, and a higher toughness, compared to one annealed in air, while the tensile yield strength is similar between the two samples. The results indicate that the sample annealed in nitrogen is more ductile than the one annealed in air. The loss of ductility in the sample annealed in air is due to oxidative chain scission.
To determine oxidation indices in these two samples, a thin film specimen of ca. 100 microns in thickness was cut from each of the 1-mm-thick annealed UHMWPE sheets and placed in an IR window for a standard FTIR (a Nicolet 710 FTIR system was used) transmission run, using the procedures and calculations employed in the Sample Preparation. Oxidation indices obtained are shown in Table 6.
TABLE 6______________________________________Sample Oxidation Index______________________________________Air Annealed 0.10Nitrogen Annealed ca. 0.0______________________________________
From the above results, it is seen that the UHMWPE sample annealed in air after ram extrusion showed significant oxidation due to free radicals generated in the forming process. In contrast, the UHMWPE sample annealed in nitrogen showed no oxidation (below the FTIR detectable level). It is concluded that annealing in nitrogen can prevent the polymer from oxidation and produce a polymer with superior ductility.
While several examples of the present invention have been described, it is obvious that many changes and modifications may be made thereunto, without departing from the spirit and scope of the invention. | 4y
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BACKGROUND
All references cited in this specification, and their references, are incorporated by reference herein where appropriate for teachings of additional or alternative details, features, and/or technical background.
Disclosed in the embodiments herein are caster suspension systems designed to accommodate uneven or irregular surfaces. In one embodiment, there is provided a caster suspension system that employs a linkage between the two casters constraining one to rise when the other falls while keeping moment internal to the system such that there is no tipping of the load carried by the caster suspension system.
Casters are well known devices that assist in the mobility of a great variety of types of equipment. They are used in industry, in the home, in the medical field, and in general whenever it is desirable to move objects over a surface.
While casters function well on smooth surfaces they tend to operate less efficiently when used on uneven surfaces or surfaces which contain irregularities, or when small objects placed upon the surface are encountered by the casters. Accordingly casters have been devised which are better adapted to maneuver over uneven surfaces. However, such prior types of devices have functional characteristics which limit their suitability for certain applications.
Certain types of casters when used on uneven surfaces are inherently unstable and can cause objects supported by them to easily tip. The possibility of tipping is increased under certain circumstances, such as when changing direction or when such a type of caster is supporting and moving a load and then encounters an object on the surface which tends to restrict its forward travel.
Other certain special types of casters significantly and abruptly change their height when contacting objects on the surface. This, in turn, causes a bump which appears to abruptly change the height of the object that is supported by such a caster.
Still other prior types of casters are able to operate only one time, and must be reset after encountering an object. Still yet other prior types of casters tend to impact with objects located upon the surface, or when they encounter uneven surfaces, which in turn results in shock being transferred to the object supported.
Reaction forces and vibrations due to uneven positioning of an instrument with respect to the floor may be particularly problematic with precision instruments (such as photolithography machines used in semiconductor processing). For instance, a photolithography machine which is subject to vibratory motion may cause an image projected by the photolithography machine to move and, as a result, be aligned incorrectly on a projection surface such as a semiconductor wafer.
For several industry products, such as high production copiers/printers, their main structure has to be designed considering the effect of uneven floor to frame integrity. If the machine does not have a relatively rigid frame and is under an uneven floor scenario (e.g., fourth caster is not co-planar with three other casters), the frame may distort and create unpredictable alignments among the internal frame components, resulting in problems such as paper registration issues, copy quality and mechanical interference between components. While one may compensate for uneven floor effect by implementing a caster adjustment (de-racking) procedure at the site, the procedure may be inaccurate due to a failure to determine a realistic reference to which to square the machine frame. Another disadvantage is that if the machine is moved, the frame will deflect again and may need to be adjusted. The latter affects service trouble-shooting and installation lines.
FIGS. 1 and 2 illustrate prior art systems 10 employing a single four-bar linkage. In FIG. 1 , casters 25 , 25 ′ are positioned in opposing directions and are linked through link connections 20 , 20 ′ to linkage bar 15 . As moments 30 , 30 ′ are in opposition directions, load 40 is balanced. However, when casters 25 , 25 ′ are moved so as to be pointing in the same direction as shown in FIG. 2 , moments 35 , 35 ′ are in the same direction and load 40 is not balanced and will tip. Accordingly, there exists today a need for a caster that is articulated to accommodate uneven surfaces and which is inherently stable.
REFERENCES
U.S. Pat. No. 5,507,069 discloses an articulated caster which provides a base having more than two casters attached thereto and disposed radially away from the approximate geometric center of the base. A pivot arm includes a pivot housing for receiving and maintaining a pivot ball therein. The pivot housing and pivot ball respectively each are provided with a pivot housing hole and a pivot ball hole which align together when the pivot ball is correctly disposed within the pivot housing.
U.S. Pat. No. 5,871,218 discloses a suspension device for preventing swivel wheel wobbling over uneven terrain of a cart, such as a shopping cart, equipped with a pair of laterally opposite swivel wheels. The suspension device consists of a rigid elongated cross-member, fixedly mounted to the cart frame; an elongated arm, defining first and second opposite ends; a first mount, for mounting the arm to the cross-member for relative movement thereabout, whereby the arm first and second ends are movable relative to the ground in opposite directions. A second mount rotatably mounts the two swivel wheels to corresponding opposite ends of the elongated arm, wherein the relative movement of the arm is responsive to ground terrain irregularities.
U.S. Pat. No. 5,903,956 discloses a three-wheel pivot-caster assembly that provides mobility for a power tool. The pivot-caster assembly includes a first frame assembly with two wheels and a second frame assembly that has a caster assembly which includes a swivel wheel.
U.S. Pat. No. 6,809,323 discloses a caster system that support portions of a stage apparatus which has a reaction frame and a stage assembly including a first caster component and at least a second caster component. The first caster component supports the stage assembly, while the second caster component supports the reaction frame and is vibrationally separated from the first caster component. The second caster component may be physically coupled to the first caster component to enable the first caster component, the second caster component, the reaction frame, and the stage assembly to be moved as a substantially single unit.
SUMMARY
Aspects disclosed herein include:
an assembly comprising a pair of casters, each caster being attached to a pitman, a frame comprising at least two pitman support features which house at least a portion of each of said pitmans configured so as to permit vertical motion of the pitman in the support but limit horizontal motion in the support, and a linkage system attaching to each of said pitmans, wherein said linkage system is operatively configured so as to cause one of the pitmans to move vertically downward when the other pitman is moved vertically upward and to hold the pitmans in place when there is no vertical motion of either pitman;
a caster load support system comprising a pair of casters, each attached to a pitman, a frame comprising two pitman support features configured to house at least a portion of said pitmans, and a linkage system attaching said pair of pitmans, said linkage system comprising a horizontal bar having a first end and a second end, a pair of first links each having a first end and a second end, the first end of each of said first links being pivotally attached to said first and second end of said horizontal bar in a manner to permit movement of said first link between an angle of about 35° to about 85° from horizontal defined by the horizontal bar, a pair of second links each being pivoted to the second end of each of said pair of first links, said second links being pivoted in a manner to permit movement between an angle of about 0° about 40° from horizontal defined by the horizontal bar, and a third pair of links, having a first end and a second end, and each of said third pair of links being pivotally attached to said second end of each of said second links and to said pitman; and
an electrostatographic system supported by an assembly comprising at least two pitman support features which house at least a portion of each of said pitmans configured so as to permit vertical motion of the pitman in the support but limit horizontal motion in the support, and a linkage system attaching to each of said pitmans, wherein said linkage system is operatively configured so as to cause one of the pitmans to move vertically downward when the other pitman is moved vertically upward and to hold the pitmans in place when there is no vertical motion of either pitman.
BRIEF DESCRIPTION OF THE DRAWINGS
Various of the above mentioned and further features and advantages will be better understood from this description of embodiments thereof, including the attached drawing figures wherein:
FIG 1 (prior art) shows a side diagrammatic view of a caster system employing a single four-bar linkage with moments in balance;
FIG. 2 (prior art) shows a side diagrammatic view of the caster system of FIG. 1 wherein moments are out of balance; and
FIG. 3 shows a side diagrammatic view of a caster embodiment system of the present disclosure.
DETAILED DESCRIPTION
In embodiments there is illustrated an assembly comprising a pair of casters, each caster being attached to a pitman, a frame comprising at least two pitman support features which house at least a portion of each of said pitmans configured so as to permit vertical motion of the pitman in the support but limit horizontal motion in the support, and a linkage system attaching to each of said pitmans, wherein said linkage system is operatively configured so as to cause one of the pitmans to move vertically downward when the other pitman is moved vertically upward and to hold the pitmans in place when there is no vertical motion of either pitman.
In such embodiment, the linkage system may be symmetrical about a point between the castors, such as the mid-line between the pair of casters. In such symmetrical design, the moment on one side of the symmetry point may be designed to be in an opposite direction to the moment on the other side of the symmetry point to keep the moments in balance and the load from tipping, flexing or bending. The casters may be attached to the pitmans through a linkage element or directly thereto. The assembly may be used to move any load including, without limitation, a printer, copier, offset press, or combination thereof.
In one embodiment, there is provided a self-leveling suspension linkage that ensures four reaction points regardless of an uneven floor scenario. Such embodiment comprises a combination of multiple bar linkages connected from one caster to another. In such embodiment, a four caster frame utilizes two sets of linkages. Such embodiment may proffer the benefits of the frame being unaffected by an uneven floor, allow the casters to freely rotate without affecting linkage functionality, minimize misalignments between internal subsystems, minimize frame racking, and reduce set-up line.
In another embodiment, there is provided a caster load support system comprising a pair of casters, each attached to a pitman, a frame comprising two pitman support features (such as, without limitation, bands of material) configured to house the pitmans (or portion thereof), and a linkage system attaching the pair of pitmans. The linkage system may comprise a horizontal bar having a first end and a second end, a pair of first links each having a first end and a second end, the first end of each of said first links being pivotally attached to said first and second end of said horizontal bar in a manner to permit movement of said first link between an angle of about 35° to about 85°, alternatively between 45° and 75°, from horizontal defined by the horizontal bar, a pair of second links each being pivoted to the second end of each of said pair of first links, said second links being pivoted in a manner to permit movement between an angle of about 0° to about 40°, alternatively between 10° and 30°, from horizontal defined by the horizontal bar, and a third pair of links, having a first end and a second end, and each of said third pair of links being pivotally attached to said second end of each of said second links and to said pitman.
Now turning to FIG. 3 , there is shown a diagrammatic side view of a self-leveling suspension linkage system embodiment of the present disclosure. As shown, horizontal link 75 divides the linkage system into two symmetrical parts, each comprising three link members 60 , 65 , 70 , and 60 ′, 65 ′, 70 ′ joined together through respective pivot points 100 , 90 , 85 , 80 and 100 ′, 90 ′, 85 ′, 80 ′. Linkage members 60 and 60 ′ are pivotably attached respective to pitmans 45 and 45 ′. Pitmans 45 , 45 ′ are held in bushings 50 , 50 ′ (respectively) connected to a load 110 that permits vertical movement up and down but limits horizontal motion of the pitman. Pitmans 45 , 45 ′ extend through a load-supporting frame 105 and are attached through caster elements 55 , 55 ′ to caster 25 , 25 ′ (respectively). Alternatively, the caster elements 55 , 55 ′ may be attached to the pitmans through a linkage element (not shown). In such a system, when the moment 115 on one symmetrical side is opposed by the moment 115 ′ on the other symmetrical side, the load 110 and system 120 remain in balance. When moments 115 , 115 ′ are in the same direction, the linkage system will cause one of casters 25 or 25 ′ to move downward until it hits the floor. The moments will then be placed into check so as to be in the opposite direction from one another.
While the invention has been particularly shown and described with reference to particular embodiments, it will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. | 4y
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application relates to U.S. Prov. Ser. No. 62/019,275 filed Jun. 30, 2014 and U.S. Prov. Ser. No. 61/981,136 filed Apr. 17, 2014; the entire contents of which are incorporated herein by reference.
FIGURE SELECTED FOR PUBLICATION
[0002]
FIG. 21
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to an induction assembly and system for a supercharged internal combustion engine. More particularly, the present invention relates to an assembly and a system having a monolithic unitary cast housing securing a super charger assembly and three integrated intercooler assemblies allowing for both a variable rate convective heat transfer via air cooling of an exterior of the monolithic cast housing and an air cooling of pressurized discharge air discharged from the super charger assembly for combustion.
[0005] 2. Description of the Related Art
[0006] Industrial applications of induction assemblies for supercharged internal combustion engines have included a plurality of complex air inlet runners and cylinder head attachments.
[0007] In one related matter in U.S. Pat. No. 6,029,637 (Prior), the entire contents of which is incorporated herein by reference, an induction assembly is provided with extended induction housing intakes related to a super charger arrangement. Here, the entrance of the intake runners is long extended providing great inconvenience in access, enhanced costs, and greater difficulty in disassembly and maintenance. Additionally as a detriment, the assembly cannot be provided in a single compact monolithic manner due to the long extended intakes and the requirement for differently shaped cylinder heads and accesses geometries.
[0008] Also in a similar detrimental arrangement is U.S. Pat. No. 7,426,921 (Billings, et al.), the entire contents of which is incorporated herein by reference, wherein a super charger arrangement is provided with a separate-piece-kit type of two-part air inlet casings that are bolted to a side of a rotor casing in combination with a top rotor casing cover member. The arrangement provided is substantially complex and is also weakened by positioning the separate two-part air inlet casings with bending moments being secured to the rotor casing only through a separate cover member. Several detriments to air flow, rigidity, and sound attenuation. Additionally, thermal release from pressurized air is greatly hampered limiting power gain substantively.
[0009] Accordingly, there is a need for an improved induction assembly and system for a supercharged internal combustion with enhanced process efficiencies and thermal release.
ASPECTS AND SUMMARY OF THE INVENTION
[0010] In response, it is now recognized that an induction system can be provided for a supercharged internal V-type combustion engine including a monolithic continuous unitary casting or housing for a supercharger with a rotor and gear assembly operative to discharge pressurized air to a common bounding receiving plenum, through a first slidably-removable intercooler providing a first cooling step, and then to a pair of second side intercoolers providing a second cooling step within the bounded plenum and in fluid communication therewith. First and second intercoolers are secured within the monolithic housing. The monolithic housing provides a robust and stable housing of light weight and compact shape. Side walls of the supercharger are separate from and are spaced from air intake runners of a cylinder block. Air in the plenum is additionally cooled by convective surface cooling of the unitary casting. The intercoolers are plumbed in parallel allowing for enhanced temperature management of the air flow in combination with the convective cooling. The monolithic housing includes a plurality of rib elements for enhanced laminar air flow cooling, sound attenuation, and strength while minimizing weight. This arrangement allows for enhanced cooling, and simplifies manufacture and service.
[0011] It is also recognized that the proposed invention additionally provides an enhanced assembly and service method, allowing a first main intercooler (which receives the most operational stress, to be slidably installed into and slidably removed from the single monolithic continuous unitary casting housing without demounting the monolithic housing from a v-type combustion engine. As a further enhancement, the proposed method of assembly and use allows for the insertion of the pair of side mounted intercoolers within the monolithic housing between the housing and runner set also allowing enhanced service and access during use.
[0012] Another proposed alternative and optional aspect to the present invention is that the single monolithic housing has a continuously bounded plenum chamber that operatively houses the central intercooler and the pair of side intercoolers within the same continuously bounded plenum chamber for enhanced and directed air flow.
[0013] In another alternative and optional aspect of the proposed invention, the monolithic housing includes inside-surface ribbing elements that provide for sound attenuation and enhanced laminar air flow while additionally enhancing the rigidity of the monolithic housing without requiring an increase in wall thickness. This bounded housing plenum houses the intercooler cores and the supercharger assembly for enhanced rigidity and a robust structure.
[0014] It is another alternative and optional aspect of the present invention that the monolithic unitary housing houses provisions for a rotating supercharger assembly with rear-exit location, a central intercooler assembly with rear-exit location, and readily accessed fluid flows and runner assemblies for enhanced access and compact shape.
[0015] The proposed assembly and system allow a variable rate convective heat transfer cooling of the combustion engine via convective external air cooling of the monolithic unitary housing and three separate, in parallel, air-to-water intercooler systems bounded within the monolithic unitary housing. Water flow through the three intercoolers (which are heat exchangers) is plumbed in parallel and discharged to a unitary heat exchanger (e.g., radiator) for heat transfer to ambient air. Water is supplied by a reflowing standalone cooling pump and reservoir system.
[0016] In another alternative and optional aspect of the proposed invention provides an induction assembly for a supercharged internal combustion engine comprising: a monolithic continuous unitary housing member, the monolithic housing member continuously bounding a bounded super charger rotor portal, a super charger access portal, a first central intercooler portal, and opposed second and third intercooler portals, and the monolithic housing member and forming a continuous bounded air distribution plenum in a flow communication from the super charger portal through the super charger access portal and to each the second and third intercooler portal.
[0017] In another alternative and optional aspect of the proposed invention an induction assembly for a supercharged internal combustion engine further comprises: a super charger having a rotor assembly operative to produced a pressurized air through the super charger access portal, a first central intercooler assembly in the air distribution plenum receiving the pressurized air and passing a first cooled air to the air distribution plenum, the air distribution plenum splitting and passing the first cooled air to a second side intercooler assembly and an opposed third side intercooler assembly, and the second and the third side intercooler assemblies passing a second cooled air to opposed air inlet members external to the monolithic unitary housing member.
[0018] In another alternative and optional aspect of the proposed invention an induction assembly for a supercharged internal combustion engine further comprises: an operative water flow system in a parallel flow communication with each the first central intercooler assembly, the second side intercooler assembly, and the third side intercooler assembly, where the second side and third side interceder assemblies are paired.
[0019] In another alternative and optional aspect of the proposed invention, an induction assembly for a supercharged internal engine is provided wherein: the first central intercooler assembly is slidably removable from the bounded continuous plenum through the first central intercooler portal, whereby an assembly and maintenance burden of the induction assembly is improved.
[0020] In another alternative and optional aspect of the present invention, a method is provided for assembly of an induction system for a supercharged internal combustion engine comprising the steps of: providing a monolithic continuous unitary housing member, the monolithic housing member continuously bounding a bounded super charger rotor portal, a super charger access portal, a first central intercooler portal, and opposed second and third intercooler portals, the monolithic housing member and forming a continuous bounded air distribution plenum in a flow communication from the super charger portal through the super charger access portal and to each the second and third intercooler portal, providing a first central intercooler assembly in the first central intercooler portal, and providing a second and a third side intercooler assembly in the respective second and third intercooler portals.
[0021] The proposed assembly and system, while maximizing the surface area for convective cooling and inner plenum surface for air flow and housing, the monolithic unitary housing may be formed in related, but different functional shapes without departing from the scope and spirit of the present invention. For example, external air-flow fins may be added to the external housing surface to provide more laminar ambient air flow surface area during vehicle movement, and these air flow fins may be shaped in numerous ways, (parallel rows, series of irregular bumps, mixture of rows and ridges, etc.). For a second example, the monolithic unitary housing may be provided in differing widths and lengths to accommodate different engine block and intake arrangements or for use with different intercooler shapes. For a further example, the proposed monolithic unitary housing may be adapted to different cylinder arrangements (4-cylinder, 6-cylinder, 8-cylinder, 10-cylinder, 12-cylinder, etc.) all within the scope and spirit of the present invention. As a result, there is no single exclusive outer surface shape or profile to the present, rather there are numerous alternatives that will meet the same functional claims and goals as noted herein.
[0022] The above and other aspects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a perspective view of the proposed inventive housing positioned relative to a vehicle hood having an air cooling portal.
[0024] FIG. 2 is a rear elevation view of a monolithic block assembly and a portion of an engine, and cylinder head, and intake runners noting a rear access portal to the intercooler and supercharger arrangement.
[0025] FIG. 3 is a side elevation view taken along section line 3 - 3 in FIG. 1 , noting the relative positions of the vehicle hood, fire wall structure, and the monolithic continuous unitary casting.
[0026] FIG. 4 is a perspective top front view of a monolithic continuous unitary casting housing a supercharger with a rotor and gear assembly operative to discharge pressurized air to a common bounding receiving plenum mounted with related components.
[0027] FIG. 5 is a perspective top rear view of a monolithic continuous unitary casting housing a supercharger as shown in FIG. 4 .
[0028] FIG. 6 is a partially exploded top rear view of FIG. 5 noting removal of the central intercooler.
[0029] FIG. 7 is top plan view of the monolithic continuous unitary casting housing a supercharger.
[0030] FIG. 8 is a partial sectional view along section line 8 - 8 in FIG. 7 .
[0031] FIG. 9 is a partial sectional view along section line 9 - 9 in FIG. 7 .
[0032] FIG. 10 is a partial sectional view illustrating air flow from a supercharger through a top intercooler and two side intercoolers.
[0033] FIG. 11 front perspective view of the monolithic continuous unitary casting noting air flow and coolant (water) flow.
[0034] FIG. 12 is a side elevation view of FIG. 11 noting the arrangement of strengthening ribs.
[0035] FIG. 13 is a front elevation view of FIG. 11 of the monolithic continuous unitary casting.
[0036] FIG. 14 is a rear elevation view of FIG. 11 of the monolithic continuous unitary casting noting the easy access to the intercooler and supercharger features.
[0037] FIG. 15 is a bottom rear perspective view of FIG. 11 noting air flow access and the interior internal geometry of the monolithic casting with ribs assisting laminar flow.
[0038] FIG. 16 is a bottom rear perspective view of FIG. 15 of the monolithic continuous unitary casting further noting the laminar air flow for cooling and operation.
[0039] FIG. 17 is a side rear perspective view of FIG. 16 noting the interior geometry for air flow as unrestricted.
[0040] FIG. 18 is a front perspective bottom view of FIG. 17 noting the interior geometry of air flow as unrestricted.
[0041] FIG. 19 is a bottom perspective view along section line 19 - 19 in FIG. 2 noting the interior ribbing and air flow structure for illustrating the continuous air flow to the side intercooler receivers from the plenum and the internal surface profile thereof.
[0042] FIG. 20 is a rear elevation exploded view of the monolithic continuous unitary casting and assembly as in FIG. 2 noting the central intercooler portal and rear access to the super charger portal.
[0043] FIG. 21 is a top rear perspective exploded and partial sectional view of FIG. 20 noting the positioning and arrangement of intercoolers.
[0044] FIG. 22 is a rear top perspective exploded and partial sectional view as in FIG. 21 noting the ease of accessibility and maintenance and improved air flow.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] Reference will now be made in detail to embodiments of the invention. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. The word ‘couple’ and similar terms do not necessarily denote direct and immediate connections, but also include connections through intermediate elements or devices. For purposes of convenience and clarity only, directional (up/down, etc.) or motional (forward/back, etc.) terms may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope in any manner. It will also be understood that other embodiments may be utilized without departing from the scope of the present invention, and that the detailed description is not to be taken in a limiting sense, and that elements may be differently positioned, or otherwise noted as in the appended claims without requirements of the written description being required thereto.
[0046] Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments of the present invention; however, the order of description should not be construed to imply that these operations are order dependent.
[0047] Referring now to FIGS. 1-10 the present invention involves an induction assembly and system 1 for a supercharged internal combustion engine having a v-type configuration (engine partially shown, but understood by those of skill in the art). As noted, a monolithic continuous unitary casting 2 housing a super charger assembly rotor assembly 6 (See FIG. 1 ) positioned relative to an automobile hood 3 (car not shown). The hood 3 includes a set of initial hood vents 3 A (see FIG. 1 ) and a hood opening 3 B bounding an upper portion of monolithic continuous unitary casting 2 . Hood 3 operates relative to a fire wall structure 8 within an engine cavity of the vehicle and a particular improvement of the present invention is to enable an operative positioning of all components within the engine cavity while allowing for maintenance without comprehensive disassembly of the vehicle engine.
[0048] As will be noted from the figures, rotor assembly and super charger 11 includes a nose drive assembly 15 operative to receive a driving force from the internal combustion engine for operative rotation.
[0049] During a use, an air intake 16 receives an air flow via hood vents 3 A and ambient atmosphere and the intake air flow is pressurized forcefully through supercharger rotor assembly 11 within monolithic continuous unitary casting 2 , and is transmitted through an access portal 11 A (See FIGS. 15-17 ) as will be discussed herein.
[0050] Monolithic unitary casting 2 includes a left side 20 A and a right side 20 b intercooler portal for receiving respective ones of a pair of side intercooler assemblies 13 , 13 before joining to respective side air intake runners 12 , 12 for transferring cooled pressurized air to the cylinder heads of the internal combustion engine. Casting 2 includes a central intercooler portal 20 C ( FIG. 10 ) and a continuously bound plenum including left and right intercooler portals 20 A, 20 B as well as a central intercooler portal 23 on a rear side thereof shaped to slidably-receive a central intercooler 14 from the rear side (see FIG. 5 ). A super charger portal 24 ″ is part of the monolithic construction and is shaped to slidingly-receive the super charger rotor assembly 11 , as shown, from a rear side, and a super charger air intake portal 24 ′ is shaped on a front side of the monolithic housing 2 . It will be understood that the super charger rotor assembly includes a nose drive assembly 15 for receiving a driving force for operation, and a rear cover door 15 A.
[0051] During an operation a water flow operates in parallel to the central intercooler assembly 14 and to each respective side intercooler assembly 13 , 13 . Water flows from a heat exchanger 6 operative to exchange heat with an ambient air, through a water pump assembly 4 , and a reservoir system 5 via a plurality of outgoing and return tubing 7 (shown respectively) to each respective intercooler assembly 13 , 13 , 14 . At a front portion of the monolithic casting 2 , a water cross over manifold 10 receives and transmits cooling water in parallel from either side intercooler assembly 13 , 13 and links with a water manifold assembly 9 for regulating an in/out flow of cooling water between each intercooler assembly 13 , 13 , 14 and the other respective elements in the water flow system 30 . As is shown particularly in FIGS. 1, 3, 4, and 5 tubing elements 7 for the central intercooler assembly 14 are shown for convenience. It will be understood by those of skill in the art of automotive engineering, after study of the present disclosure that the flow elements of water flow system 30 may be modified and positioned differently and remain within the scope and spirit of the present invention. The present arrangement shown provides an improved convenience but is not limited thereto. For example, additional pumps, different reservoirs, and different pumps, cross-over manifolds and other separate manifolds may be used without departing from the present invention.
[0052] The interior surface of monolithic continuous unitary casting 2 includes a central rib member 21 (see FIGS. 10, 16 for example) to aid in directionally bifurcating the laminar pressurized air flow exiting intercooler 14 . A plurality of lateral rib members 22 project generally perpendicularly away from central rib member 21 along the inside surface of casting 2 to further aid and generate laminar airflow to respective side intercooler assemblies 13 , 13 . It will be understood that internal ribs 21 , 22 guide efficient pressurized laminar air flow, manage sound attenuation to reduce noise, and aid stiffening of casting 2 .
[0053] At a bottom location of monolithic continuous unitary casting 2 , below super charger rotor assembly 11 and super charger portals 24 ′, 24 ″ are provide a plurality of rotor support ribs 25 projecting outwardly therefrom (see FIGS. 12, 16 , and 18 ). Ribs 25 provide an additional rigidity and thermal conduction to casting 2 while enabling a thin wall section in the casting for a substantial weight reduction.
[0054] Referring additionally to FIGS. 11-22 additional sectional views are provided to aid in comprehension of induction assembly and system 1 , monolithic continuous induction housing 2 , and the related positions of central intercooler 14 and side intercoolers 13 , 13 relative to runners 12 , 12 .
[0055] As will well understood from the cross-sectional arrangements in FIGS. 8, 9, 10, 15, and 19 , the induction housing 2 is continuous as a monolithic member having a thin wall thickness. In this matter, induction housing 2 can advantageously be assembled and removed from a set of cylinder heads 35 , 35 and a respective cylinder block 40 provided for illustrative purposes and to illustrate an overall block assembly 41 containing these basic components. As a result, it will be recognized by those of skill in the art that induction assembly and system 1 may be readily incorporated with cylinder heads 35 , 35 and cylinder block 40 and overall block assembly 41 having various geometries, within the scope and spirit of the present invention.
[0056] As will be understood from considering side elevation view of block assembly 41 in FIGS. 2, 21 , there is enabled by the present invention, an air gap (shown) between the bottom super charger ribs 25 and the central portion of cylinder block 40 , allowing for additional cooling, as well as other advantages in terms of efficiency and engine-component-arrangement.
[0057] It will be understood that monolithic continuous unitary casting 2 may be alternatively called a monolithic housing 2 , for convenience without departing from the scope and spirit of the present invention.
[0058] It will be noted that side intercooler assemblies 13 , 13 are provided within left and right intercooler portals 20 A, 20 B (see FIGS. 14, 15, 16 ), and are positioned within monolithic housing 2 allowing for easy access upon simple removal of monolithic housing 2 for maintenance. As will be noted, monolithic housing 2 contains a series of bolt holes (16 in total shown) respectively identified as openings 26 . As will be appreciated from study of the figures, bolt holes 26 are continuous through monolithic housing 2 and extend through either side walls of the respective outer sides of monolithic housing 2 or are fully enclosed passages through the interior sides of the continuous bounded plenum within housing 2 (see for example, FIGS. 10, 16, 17, 18 , where it can be seen that laminar air flows pass from central rib 21 region along lateral rib regions 22 directly to side intercooler assemblies 13 , 13 and directly therethrough. It is noted that with the full enclosure of bolt holes 26 that tightening during assembly cannot distort unitary casting 2 because any bolt is continuously supported by the bolt-hole-side-wall (See FIG. 9 )
[0059] As will be understood from the disclosure, and particularly from FIGS. 5 and 6 , as a substantial convenience central intercooler 14 may be accessed in a slide-out manner from the rear of monolithic housing 2 without removal of monolithic housing 2 from any other engine component. In process, for assembly or disassembly, this is a substantial time savings and quality improvement. Specifically, there is no damage to any seal (which is not effective by sliding removal) between the monolithic housing 2 , and runners 12 , 12 , or any other component. The rear door access portal 11 A for supercharger rotor assembly 11 need not be opened for changing or inspecting central intercooler 14 . Additionally, as a substantial benefit, side intercooler assemblies 13 , 13 may also be inspected via angled viewing through (via) the central intercooler portal 23 , providing an enhanced and very fast review. An inspection light (not shown) can be positioned within portal 23 (see FIG. 6 ) and each side intercooler 13 , 13 can be inspected without the need to remove monolithic continuous unitary casting 2 unless necessary.
[0060] Regarding the position of monolithic housing 2 positioned within hood opening 3 B; during use, variable rate air flow flows over a pair of undulating outer surface region 27 , 27 for monolithic housing 2 , spaced by a smooth central surface region 28 . Undulating outer surface regions 27 , 27 receive deflected air flow from central surface region 28 , which deflects laterally (to the side) due to a curved and slanted/angular arrangement. Additionally, any direct air flow (from the front of a vehicle) undulates over undulating out surface regions 27 , 27 and mixes with the laterally deflected air flow. This combined air flow intermixes for an enhanced convection heat transfer from the surface of monolithic housing 2 during vehicle transfer.
[0061] Additionally, it will be understood that the rear-portion of monolithic housing 2 (see FIGS. 5, 6, 7, 12, 15-18, and 21-22 ) splits into two side ‘boot’ type portions (shown but not numbered) proximate the ends of relating left and right intercooler portals 20 A, 20 B and intakes and cylinders for the respective engine. In this way, it will be understood that the laminar air flow extends to the entire cylinder head bank and to the cylinder heads and is not detrimentally affected despite the split shape. This arrangement additionally allows a convenient sealing between respective air runners 12 , 12 and monolithic housing 2 , a convenient shape, and reduced weight for the overall engine and induction assembly 1 .
[0062] It will be further understood that the proposed assembly and system, while maximizing the surface area for convective cooling and inner plenum surface for air flow and housing, the monolithic unitary housing may be formed in related, but different functional shapes without departing from the scope and spirit of the present invention. For example, external air-flow fins may be added to the external housing surface to provide more ambient air flow surface area during vehicle movement, and these air flow fins may be shaped in numerous ways, (parallel rows, series of irregular bumps, mixture of rows and ridges, etc.). For a second example, the monolithic unitary housing may be provided in differing widths and lengths to accommodate different engine block and intake arrangements or for use with different intercooler shapes. For a further example, the proposed monolithic unitary housing may be adapted to different cylinder arrangements (4-cylinder, 6-cylinder, 8, cylinder 10-cylinder, 12-cylinder, etc) all within the scope and spirit of the present invention. As a result, there is no single exclusive outer surface shape or profile to the present, rather there are numerous alternatives that will meet the same functional claims and goals as noted herein.
[0063] Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it will be apparent to those skills that the invention is not limited to those precise embodiments, and that various modifications and variations can be made in the presently disclosed system without departing from the scope or spirit of the invention. Thus, it is intended that the present disclosure cover modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents.
REFERENCE DESIGNATOR LISTING
[0000]
1 : induction assembly and system for a supercharged internal combustion engine
2 : monolithic continuous unitary casting housing
3 : hood
3 A: hood vents
3 B: hood opening
4 : water pump
5 : water/coolant reservoir
6 : heat exchanger to ambient air
7 : tubing
8 : fire wall structure
9 : water manifold
10 : water cross over manifold
11 : rotor assembly
11 A: access portal (for pressurized air)
12 , 12 : runners (2)
13 , 13 side intercooler assembly (2)
14 : central intercooler assembly
15 : nose drive assembly for super charger
15 A: cover door
16 : air intake
20 A: 20 B left side and right side intercooler portals
21 : central rib interior
22 : lateral ribs
22 : lateral ribs interior
23 : central intercooler portal
24 ′: super charger rotor portal
24 ″: super charger air intake portal
25 : super charger rotor support ribs
26 : bolt holes, collectively
27 , 27 : undulating outer surface region (2)
28 : smooth central surface region
30 : water flow system
35 : cylinder head(s)
40 : cylinder block
41 : block assembly | 4y
|
CROSS REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 417,888, filed Nov. 21, 1973 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to pollution control systems, and more particularly provides an emission control system for an internal combustion engine. While not so limited, the invention is particularly applicable to automotive and other moving vehicle engines, where the low temperatures obtained as an adjunct may be employed to air-condition or refrigerate part of the vehicle.
The intensified search for improved emission control systems for internal combustion engine has spawned a multitude of proposals. At present, three basic systems have emerged: catalytic treatment of the exhaust gases, after-burners to complete the combustion of exhaust gases, and modification of the engine operating parameters to minimize the amount of emission. Catalysts, however, are readily contaminated by lead compounds in the gases; after-burners require additional fuel; and alteration of operating parameters (e.g. compression ratio, spark timing, etc.) has caused deterioration in gas mileage.
Accordingly, an object of the invention is to provide an emission control system for internal combustion engines which system requires no lead-susceptible catalysts, no fuel-consuming after-burning, and no alteration of the engine itself. An additional object is to provide such system in a form which is particularly applicable to moving vehicles, especially passenger cars, which are driven under a variety of traffic and atmospheric conditions.
Further, an important object of the invention is to provide an emission control system for vehicles, which system produces a low-temperature effluent that can be utilized for air-conditioning or for refrigeration purposes. Thus, as a result of this feature, the installation of an emission control system in an automobile or truck, with little further investment or operating cost, provides the vehicle with a self-contained air conditioning system.
Still other and further objects include the provision of a low cost, durable, and essentially trouble-free emission control system; an emission control system which permits ready withdrawal and disposal of concentrated pollutants; a system which requires no periodic replacement of catalyst inventory; a system which actually enhances the combustion efficiency of an internal combustion engine by reducing the exhaust back-pressure; and a system which permits ready manual or automatic adjustment of flows to optimize engine operation, pollution elimination, and/or refrigeration, depending upon the local demands of temperature, traffic, and legal conditions.
SUMMARY OF THE INVENTION
Briefly, in accordance with the invention, a system is provided for controlling emissions from an internal combustion engine by initially cooling the exhaust gases from such engine, then compressing, again cooling, and work-expanding the exhaust gases to further cool them to a temperature sufficient to condense a substantial portion of the pollutants as a separable liquid or solid phase, and thereafter separating the pollutants-containing phase from the remaining exhaust gases. Thus, pollutants are removed from the exhaust gases by cooling the gases to a temperature sufficiently low so that the pollutants condense out, and the cleaned exhaust gases are discharged to the atmosphere.
The system of the invention is particularly suitable for utilizing a unitary rotary compressor-expander, of the type described in U.S. Pat. No. 3,686,893, as a device for both adiabatically compressing the exhaust gases and for work-expanding the cooled compressed exhaust gases. With such a rotary compressor-expander, thermodynamic efficiency is maintained at a high level, while investment, operating, and maintenance costs are retained sufficiently low as to be suitable for passenger automobiles.
A particularly advantageous feature of the invention is that, with minor modification, it provides refrigeration or air conditioning as well as pollution control. Thus, with little additional equipment--and no conventional auxiliaries such as extra compressors, refrigeration fluids, or the like--a cool or cold air stream can be provided for passenger air conditioning or for vehicle refrigeration.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent from the following detailed description and upon reference to the drawings, in which:
FIG. 1 is a generalized schematic top view of an automobile engine compartment, in which the inventive system is employed in alternative arrangements for maximizing either pollution control or refrigeration and air conditioning; and
FIG. 2 an exploded perspective view of a combined or unitary rotary compressor-expander advantageously used in the system of FIG. 1.
While the invention will be described in connection with a preferred embodiment as illustrated in the drawings, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning first to FIG. 1, a detailed schematic top view of an illustrative dual-service installation is depicted. In substance, the engine compartment 10 of a vehicle 11, which contains an internal combustion engine 12 such as a reciprocating or turbine engine, is equipped with a compressor-expander 14 for compressing the engine exhaust gases and, after cooling the compressed gases in an intercooler 15, for work-expanding the gases to an exhaust discharge pressure. The resulting work-expanded gases are at a sufficiently low temperature to permit a substantial portion of the pollutants to condense out as separable solids or liquids, and these are removed and discarded.
The engine 12, which may be of conventional type, discharges its exhaust gases through an exhaust gas header 16. These exhaust gases, when obtained from the combustion of liquid hydrocarbon fuels such as gasoline or diesel fuel using air as the oxidant, will contain both completely and incompletely oxidized products of combustion. The composition of such exhaust gases varies with fuel composition, fuel/air ratio, the type of engine, and the engine combustion parameters, as well as uncontrollable factors such as incoming air temperature and humidity, etc. For any given set of conditions, the gas composition at equilibrium may be calculated from data contained in, for example, Hottel et al., "Thermodynamic Charts or Combustion Processes", Parts One and Two (John Wiley & Sons, Inc., 1949).
Exhaust gases from an internal combustion engine are composed of both condensible and non-condensible compounds. The non-condensibles include nitrogen (boiling point -320°F), oxygen (B.P. -297°F), hydrogen (B.P. -423°F), carbon monoxide (B.P. -310°F), carbon dioxide (B.P. -109°F), nitric oxide [NO] (B.P. -291°F) and, to some extent, nitrogen dioxide [NO 2 ]. Condensible gases include water vapor (B.P. +212°F), sulfur dioxide [SO 2 ] (B.P. +14°F) and, importantly, unburned and partially burned (oxidized) hydrocarbons, including alkehydes, ketones, peroxides, alcohols, and the like. The gases also contain oxidation products of tetraethyl and/or tetramethyl lead, which is normally a finely divided, almost colloidal, oxide or halide.
From the standpoint of emission control, unburned and partially burned hydrocarbons, nitrogen dioxide, sulfur dioxide, and lead compounds are the particularly serious offenders. Unburned and partially burned hydrocarbons are believed to react with nitrogen dioxide under the influence of sunlight to produce the intensively irritating photochemical smog. See, in particular, Kirk and Othmer's "Encyclopedia of Chemical Technology," Second Edition, Supplement Volume, Section on `Automobile Exhaust Control`, at page 50, et. seq. Consequently, their removal is a desirable goal of all exhaust emission control systems, and is largely achieved through the system of the present invention.
Lead compounds have long been recognized as having two adverse pollution effects. First, they are potent catalyst poisons for many catalysts that have heretofore been proposed for emission control systems. And second, their introduction into the atmosphere and thereafter into human lungs may present an independent toxicity problem.
In keeing with the invention, condensible pollutants including unburned and incompletely burned hydrocarbon, tetraalkyl lead combustion products, and some of the other deleterious compounds, e.g. nitrogen dioxide, are removed from the exhaust gases by a multiple stage cooling, compression, re-cooling, and expansion system. To this end, the exhaust gases from the engine 12 are conducted from the exhaust gas header 16 through an exhaust gas manifold 18 and then to a first heat exchanger 19, where the gases are cooled by indirect heat exchange with incoming air to the engine compartment 10. The heat exchanger 19 may, as shown, be located downstream of the engine 12, and preferably also downstream of the conventional radiator 20 for the engine and an intercooler 15 for the compressor-expander 14. In any event, the heat exchanger 19 reduces the temperature of these exhaust gases from several hundred °F, to approximately, 150°F or so for subsequent processing.
After the heat exchanger 19, the exhaust gases in the manifold 18 may be conducted to an optional second heat exchanger 21 where, in the maximum thermal efficiency mode, the exhaust gases exchange heat with expanded and cooled air discharging from the vehicle through a tail pipe 22, to be described presently.
After cooling in the heat exchanger 19 and the optional exchanger 21, exhaust gases may then be sent to an optional catalytic converter 24 for catalytic oxidation of unburned and partially burned hydrocarbons to carbon oxides, and/or decomposition of nitrogen oxides to nitrogen and oxygen gases. While catalytic converters are not essential in the present system, they are advantageous from the standpoint of removing nitrogen oxides in particular, as these constituents are especially offensive from a smog-producing standpoint and are incompletely removed in the system of the invention. Catalysts such as vanadium oxides, molybdenum oxides, precious metals such as platinum and palladium, are well known; see the Kirk-Othmer reference cited above.
For reasons of efficiency, economy, and simplicity, a unitary compressor-expander 14 is best employed for compression of the exhaust gases. As exemplified in U.S. Pat. No. 3,686,893 and in FIG. 2 herein, the compressor-expander 14 is of the rotary vane type, which utilizes a cylindrical rotor 25 provided with a plurality of radially-extending vanes 26, which rotates within a substantially elliptical stator 28. The term "vanes" as used herein will be understood to broadly include any partition means defining chambers which are progressively compressed in size, and enlarged, for the compressor and expander functions. The stator 28 is provided with gas inlet ports 29 from the exhaust manifold 18, with gas discharge ports 30 leading to the intercooler 15, with gas return inlet ports 31 leading back to the stator 28 elliptical cavity, and with expanded gas outlet ports 32 extending to the tail pipe 34.
As more fully explained in U.S. Pat. No. 3,686,893, the rotor 25 may be equipped with a series of slots disposed axially on the otherwise-solid rotor, and which receive axial flat-bladed vanes 26. The slots are arranged symmetrically around the circumference of the rotor; auxiliary provisions may be included for insuring close sliding contact between the outermost edges of the vanes 26 with respect to the rotor cavity 28, while end seals minimize leakage around the end faces (not shown) of the stator 28.
When the rotor 25 is rotated within the elliptical stator 28 and the vanes 26 are in sliding contact with the elliptical cavity, exhaust gases from the manifold 18 enter the cavity via the ports 29 and are compressed by the action of the vanes 26 relative to the progressively confining space between the rotor and stator. This compression is essentially adiabatic, except for incidental heat losses in the compressor-expander 14.
Compressed exhaust gases discharge from the stator 28 via the discharge ports 30 at a pressure illustratively on the order of 35 psig and at a temperature of typically about 300°F, although both the pressure and the temperature are functions of the compressor design and the inlet pressure and temperature of the exhaust gases at the manifold 18. These compressed gases must then be cooled to a temperature approaching that of the ambient atmosphere.
An additional feature of the invention resides in the fact that the compressed exhaust gases downstream of the compressor-expander and prior to the intercooler 15 are in an ideal condition for optional treatment for emission removal by reason of the higher-than-manifold pressure existing downstream of the intercooler 15. Thus, in keeping with this feature of the invention, a catalytic converter 25 (FIG. 1) is interposed in the conduit between the compressor-expander 14 and the intercooler 15 so that the compressed, heated, exhaust gases are subjected to contact with a catalytically active medium in the converter 25.
Catalysts and catalytic converters for automotive exhaust emission control have been described by others; see, for example, Kirk-Othmer's "Encyclopedia of Chemical Technology", Second Edition, Supplement Volume, Pages 62-67. Thus, where additional hydrocarbon oxidation is desired, conventional oxidation catalysts such as the vanadium oxide and/or molybdenum oxide type are preferably employed. For carbon monoxide oxidation, the supported noble metal catalysts are favored, as for example platinum or palladium on alumina. Where nitrogen oxide control is most important, the noble metal catalysts appear to be preferred. Physically, the catalysts may be disposed in any desirable configuration, e.g. radial flow converters, down flow converters, and axial flow converters.
A notable feature of catalytic converters located downstream of the compressor-expander 14 is that the exhaust gases are at a higher pressure than are the exhaust gases from similar internal combustion engines which do not utilize a compressor-expander 14 or similar device. Because the pressure existing in the converter 25 is nominally three times higher than conventional exhaust pressures, a reduced quantity of catalysts may be employed for equivalent contact times. Additionally, the higher pressure existing in the present system favors catalytic reactions of the type presently of interest.
Interstage cooling is effected in an air-cooled intercooler 15 located forwardly of the engine radiator 20 (FIG. 1). The design of this intercooler is important from the standpoint of downstream operation of the emission control system, as the more efficient the intercooler is the lower is the ultimate temperature that can be achieved, and consequently the more effective is the pollutant removal.
Be that as it may, the compressed and cooled exhaust gases leaving the intercooler 15 flow through a conduit 35 and thence to the expander section of the compressor-expander 14. Here, the gases assist in rotating the rotor 25 and thereby are reduced in pressure and cooled substantially; temperatures of -40°F are readily attained in the tail pipe 34 leaving the expander section of the compressor-expander 14.
Reducing the exhaust gas temperature to temperature below the dew point of the exhaust gas has several simultaneous effects. First, some or even most of the water vapor is condensed as either liquid water droplets or as fine snow or ice, depending on the temperature. Second, the formation of such a liquid or solid phase accumulates many of the heretofore difficulty removable pollutants, especially tetraalkyl lead decomposition products, which are otherwise too fine for removal by conventional filtration techniques; these moreover, may act as nuclei for water droplet or ice particle formation which additionally facilitates condensation of the water. Third, the formation of a low temperature liquid or solid phase, highly dispersed, assists in the accumulation of condensible unburned and partially burned hydrocarbons, which concurrently agglomerate with the water or ice. And fourth, a portion of the condensible gases, e.g. sulfur dioxide and nitrogen dioxide, along with a portion of the carbon dioxide, either condense or dissolve in the water or ice phases.
As a result of this combined cooling and condensation, many of the most troublesome pollutants are contained within a condensed liquid or solid phase, and may readily be excluded from the remaining exhaust gases.
Separation of the solid and/or liquid pollutants, including water or ice as the case may be, is effected in a separator 36 where the particles are physically removed from the gas phase. The separator 36 is advantageously a physical separator such as a cyclone or series of cyclones, a baffled chamber, a foraminous demister, or a filter, depending upon whether the condensed pollutants and water are likely to be liquids or frozen solids. This, of course, depends upon the design parameters for the compressor-expander 14, as described in U.S. Pat. No. 3,686,893. The condensed pollutants and water are then accumulated in a storage vessel 38, where they are periodically discharged.
If desired, a physical separator such as a cyclone separator 36 may be integrated with a chemical separator for further reduction of pollutants. Thus, for example, an alkaline material such as lime or soda ash may be employed to react with acidic pollutants, e.g. the nitrogen oxides and carbon dioxides, and while this adds to the operating cost of the system it may be required under especially stringent pollution control regulations.
The pollutant-denuded effluent gases leaving the separator 36 continue through the tail pipe 34. At this stage, most of the harmful pollutants have been removed, and the still-cold gases may be disposed of in any of several ways. They may, for example, merely be discharged to the atmosphere.
For optimum utilization of the low temperatures obtained in the exhaust gas, several alternative arrangements are available for optimizing either thermodynamic efficiency, or pollutant removal, or for producing refrigeration or air conditioning.
To obtain maximum thermodynamic efficiency, a valve 39 in the tail pipe 34 may be employed to direct the cold gases via a conduit 22 to the optional heat exchanger 21 located downstream of the main heat exchanger 19. Thus, the cold exhaust gases are available to chill the initial engine exhaust before the exhaust is compressed by the compressor section of the compressor-expander 14.
Alternatively, for very low emissions, the valve 39 may be employed to direct the chilled exhaust gases through a conduit 40 to a heat exchanger 41 downstream of the intercooler 15. The exchanger 41 is, in this case, connected via three-way valves 44, 45 so as to exchange with compressed and cooled gases leaving the intercooler 15, and thereby produce additional cooling of the compressed gases prior to their expansion.
In most instances, however, the user will find it more attactive to employ the chilled exhaust gases as a direct source of refrigeration or air conditioning for the vehicle or vehicle contents. To this end, the valve 39 in the tail pipe 34 is opened so as to permit all, or a substantial portion of, the chilled exhaust gases leaving the separator 36 to flow through a coolant conduit 46 and heat exchange fins 48 en route to the tail pipe 49. Fans 50 direct atmospheric air over the fins 48, which is then cooled to a temperature sufficiently low as to be suitable for air conditioning of the passenger compartment or refrigeration of a truck requiring continuous refrigeration.
Thus it is apparent that there has been provided, in accordance with the invention, a simple, practical, system for reducing or removing pollutants from engine exhaust gases. The system is especially effective in removing hydrocarbons, partialy burned hydrocarbons, and lead particles, all without requiring major engine modification or the provision of expensive, troublesome, afterburners, catalysts, or the like. Further, the system provides a chilled stream which is available for air conditioning or refrigeration, thereby obviating the cost of specific equipment used for those purposes. | 4y
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BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to component placement machines and, more particularly, to an apparatus used for rejection of a component during the placement cycle.
2. Related Art
The use of sophisticated placement machines in manufacturing printed circuit or similar cards, boards, panels, etc. is well known. The term printed circuit board (PCB) as used herein refers to any such electronic packaging structure. Typically, reels of tape-mounted circuit components are supplied to the placement machine by multiple feeders. Each feeder holds a reel of components and each feeder assembly provides components at a pick station. A housing carrying one or more pick/place heads mounted on a frame, each pick/place head having a vacuum spindle equipped with a nozzle, may be moved in the X and Y axes in a plane above the PCB being populated. Each vacuum spindle may be moved in the Z-axis (e.g., in and out from an extended to a retracted position). Each nozzle is sized and otherwise configured for use with each different size and style of component to be placed by the machine.
In operation, the housing carrying the frame is moved to the pick station and the nozzle of one of the pick/place heads is positioned over the tape-mounted component. The nozzle is lowered, via its associated vacuum spindle, to a point where, upon application of vacuum, the component is removed from its backing tape and held tightly against the nozzle orifice. The component is then brought to a vision system where one or more images of the component are taken and then processed.
Analysis of the image(s) determines whether the component is placeable. Typically, a placeability decision is based on a comparison of the image to predetermined mechanical parameters for each component. If the component is placeable, the pick/place head is moved to a point over the printed circuit board being assembled and the component deposited on the printed circuit board at a predetermined location. If a component is non-placeable, it is rejected and deposited to a reject station. The mechanical parameters used for comparison may include, but are not limited to, lead length, lead width, lead spacing, component size, the number of leads, etc.
It is also known in the art to use a gripping mechanism that may be extended and retracted in place of, or in addition to, the vacuum spindle and nozzle.
This reject station may be a dump bucket, a reject feeder, or a matrix tray. Dump buckets typically are mounted somewhere accessible to the pick/place head within the placement machine or mounted on the housing contiguous with the pick/place head. The pick/place head carrying a rejected component will place the component on to the reject feeder, or into a pocket of the matrix using the vacuum spindle. However, when the pick/place head must reject the component into a dump bucket, it drops the component from the vacuum spindle often using a combination of vacuum removal and “airkiss”. Many times components rejected in this manner miss the dump bucket or bounce out of the dump bucket upon depositing therein and ultimately end up else where in the machine. This results in poor product, jammed feeders, and poor production rates.
A need exists for an improved rejection station that overcomes the aforementioned, and other, deficiencies in the art.
SUMMARY OF THE INVENTION
The present invention provides an improvement in the way that non-placeable components are handled in a component placement machine when rejected into a dump bucket style reject station. The inventive apparatus allows the dump bucket to retain the rejected components by attaching a flap to the dump bucket. The flap dampens the force of the component as it enters the dump bucket and then prevents the component from escaping the dump bucket once the component passes by the flap. Therefore, with the flap attached to the dump bucket, components no longer escape the dump bucket resulting in inter alia better product and production rates of the placement machine.
A first general aspect of the present invention is a method for rejecting a component from a pick/place head in a component placement machine, the steps comprising:
providing a component placement machine comprising a housing adapted for movement along an X and a Y axis above a printed circuit board and having a frame attached thereto, said frame having a one or more pick/place heads disposed thereupon; providing a vision system comprising a camera accessible to said one or more pick/place heads; picking a component from a supply of components using at least one of said one or more of pick/place heads; capturing an image of said picked component, and processing said captured image to determine whether said picked component is placeable or non-placeable; providing a reject station adapted to receive a component; adapting said reject station with means to reduce the force upon which said component impacts said reject station; and adapting said reject station with means to prevent said component from escaping said reject station.
A second general aspect of the present invention is a apparatus for retaining a rejected component from a pick/place head in a component placement machine, the apparatus comprising:
a reject station mounted in a location accessible by said pick/place head; and at least one flap mounted contiguous with said reject station, wherein said at least one flap dampens the force in which said component impacts said reject station, further wherein said at least one flap prevents said component from escaping said reject station.
A third general aspect of the present invention is an apparatus for retaining rejected components in a component placement machine comprising:
a reservoir for retaining said rejected components; and means adjacent to said reservoir, wherein said means is configured to absorb adequate energy from said rejected component upon its passage through said means, further wherein said means prevents said rejected component from passing back through said means thereby retaining said rejected component in said reservoir.
BRIEF DESCRIPTION OF THE DRAWINGS
A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent detailed description, in which:
FIG. 1A is a top, perspective view of a related art dump bucket;
FIG. 1B is a side, sectional view FIG. 1A , including a spindle;
FIG. 2A is a top, perspective sectional view of a related art reject station that may be mounted contiguous with the pick/place head;
FIG. 2B is a side, sectional view FIG. 2A , including a spindle;
FIG. 3A is a top, perspective view of a first embodiment of a component rejection station, in accordance with the present invention;
FIG. 3B is a side, sectional view FIG. 3A , including a spindle;
FIG. 4A is a top, perspective view of a second embodiment of a component rejection station, in accordance with the present invention; and
FIG. 4B is a side, sectional view FIG. 4A , including a spindle.
DETAILED DESCRIPTION OF THE INVENTION
Although certain embodiment of the present invention will be shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present invention will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of an embodiment. The features and advantages of the present invention are illustrated in detail in the accompanying drawings, wherein like reference numerals refer to like elements throughout the drawings.
The present invention pertains to rejection of a component in a component placement machine having a housing with a frame upon which one or more pick/place heads are mounted for assembling printed circuit boards. The component placement machine includes a reject station, which may be a dump bucket located within the placement machine accessible to the pick/place head or it may be mounted on the housing contiguous with the pick/place heads. The inventive apparatus includes a flap contiguous with the reject station which acts to dampen the force of the component as it enters the reject station and then prevents the component from escaping the reject station once the component passes by the flap. The type of components that typically are rejected and stored by the invention are electronic circuit components with a weight in the range from approximately 50 micrograms to 15 grams.
Turning now to FIG. 1A , which depicts a dump bucket 10 that would be mounted in a machine accessible to the pick/place head from the related art, said dump bucket 10 includes an opening 20 that leads to a reservoir 25 for retaining rejected components(s) 50 (See e.g., FIG. 1B ). The side sectional view in FIG. 1B shows a vacuum spindle 30 with nozzle 40 having just deposited a rejected component 50 into the reservoir 25 of the dump bucket 10 . A trajectory path 60 of the rejected component 50 shows that upon the impact point 61 of the component 50 on a portion of the reservoir 25 , that in many cases the component 50 then bounces out of the opening 20 of the reservoir 25 and dump bucket 10 .
Similarly, FIGS. 2A and 2B depict a second embodiment of a dump bucket 10 that would be mounted contiguous to the pick/place head in the related art, wherein the same shortcoming exists. That is upon the depositing of the rejected component 50 , on many occasions, the component 50 ultimately ends up outside the dump bucket 10 . One trajectory path 60 is shown as an example of one typical path that the component may take. That is the component 50 makes a series of impacts 61 A, 61 B, 61 C, 61 D on various parts of the reservoir 25 , or other parts of the dump bucket 10 , ultimately ending up beyond the opening 20 of the dump bucket 10 .
It should be apparent to those of ordinary skill in the art, that while some rejected components 50 are retained within the reservoir 25 of the dump bucket 10 , one or more components 50 clearly will be ejected out of the dump bucket 10 as shown in FIGS. 1B and 2B . The present invention corrects this deficiency by ensuring that no components 50 escape the dump bucket 10 .
Referring first to FIG. 3A there is shown a top, perspective view of a first embodiment of a dump bucket 10 , or component rejection station, in accordance with the present invention, with opening 20 , adapted with a flap 80 . FIG. 3B is a side, sectional view of FIG. 3A and includes the path 60 of the component 50 as it is rejected from the vacuum spindle 30 of nozzle 40 . The vacuum spindle 30 releases the component 50 by removing vacuum from the nozzle 40 . Vacuum spindle 30 may also release the component 50 by a combination of removing vacuum from the nozzle 40 and applying an airkiss, a slight flow of air, to component 50 via nozzle 40 . Component 50 becomes disengaged from nozzle 40 and drops on to flap 80 . The first impact of the component 50 is denoted 61 A. Flap 80 is then deflected allowing component 50 to pass through the opening 20 into the bottom of dump bucket 10 . A second impact 61 B of the component is shown at the bottom of the reservoir 25 . When component 50 impacts flap 80 , flap 80 absorbs force from component 50 slowing the descent of component 50 . Component 50 may then continue to bounce within dump bucket 10 . Subsequent impact of the component 50 upon the underside of the flap 80 is shown 61 C. However since the force of component 50 was reduced by flap 80 upon passage through opening 20 , it does not have sufficient energy to pass back through opening 20 via flap 80 . The component 50 ultimately comes to rest upon the bottom of the reservoir 25 , as shown at 61 D.
Referring next to FIG. 4A which depicts a second embodiment of a component rejection station which is mounted contiguous with pick and place spindles, in accordance with the present invention. In this case, the component rejection station includes a dump bucket 10 , with opening 20 , adapted with flap 80 . FIG. 4B , similarly, is a side sectional view of FIG. 4A and includes the path 60 of the component 50 as it is rejected from the vacuum spindle 30 of nozzle 40 . The various impacts of the rejected component 50 are denoted 61 (e.g., 61 A, 61 B, 61 C, 61 D, 61 E, 61 F). The vacuum spindle 30 releases the component 50 by removing vacuum from the nozzle 40 . Vacuum spindle 30 may also release the component 50 by a combination of removing vacuum from the nozzle 40 and applying an airkiss, a slight flow of air, to component 50 via nozzle 40 . Component 50 becomes disengaged from nozzle 40 and drops on to flap 80 . The impact upon the flap 80 is denoted 61 A. Flap 80 is then deflected allowing component 50 to pass through the opening 20 into the bottom of the dump bucket 10 . When component 50 impacts 61 A flap 80 , flap 80 absorbs force from component 50 slowing the descent of component 50 . Component 50 may then continue to bounce within the reservoir 25 of the dump bucket 10 . However since the force of component 50 was reduced by flap 80 upon passage through opening 20 , it does not have sufficient energy to pass back through opening 20 via flap 80 . Numerous subsequent impacts of the component 50 are shown as 61 B, 61 C, 61 D 61 E, while the final resting location of the component 50 upon the bottom of the reservoir 25 is denoted as 61 F.
It should be apparent that although two embodiments of the present invention are depicted there are other embodiments available that provide the requisite improvements of the present invention. For example, the flap 80 , while depicted as either a single flap 80 (e.g., FIGS. 4A , 4 B) or two opposing flaps 80 (e.g., FIGS. 3A , 3 B), may have other embodiments. The flap 80 may be, for example, more than two flaps 80 . In the embodiments where there is a plurality of flaps 80 , the various flaps 80 may also abut or overlap each other. Further, the flap(s) 80 may, depending on the configuration and shape of the opening 20 and other parts of the dump bucket 10 , not abut, or overlap, each other, or even completely cover the opening 20 .
Likewise, there are various materials in which the flap 80 may be constructed. The flap 80 should be of a resilient, energy-absorbing material so that various sized rejected components 50 may pass by the flap 80 upon initial contact, yet cannot pass through a second time, or any subsequent time, upon the rebounding of the component 50 around the reservoir 25 of the dump bucket 10 . One embodiment the flap 80 may be made of Mylar®. Alternatively, the flap 80 may be made of multiple materials.
Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention. | 4y
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BACKGROUND OF THE INVENTION
The present invention relates to an arrangement for elevating liquid by the use of solar and/or wind energy.
Arrangements of the above mentioned general type are known in the art. One of such arrangements is disclosed for example in the U.S. patent application Ser. No. 441,740 filed Nov. 15, 1982, now U.S. Pat. No. 4,519,749. In this arrangement a first pipe immersed in a liquid is connected by another pipe with a second pipe which is directed upwardly with entrapment of the liquid in the interconnection, and means causing a pressure differential and forming an air passage alternately and repetitively during the presence of solar and/or wind energy. The above mentioned arrangement operates very effectively. However, liquid in the second pipe can slowly flow downwardly into the interconnection in the absence of solar and/or wind action and at least partially close the same thus reducing efficiency of the arrangement. It is therefore desirable to eliminate this disadvantage.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an arrangement which avoids the disadvantages of the prior art.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in an arrangement for elevating liquids by the use of solar and/or wind energy, in which purging means is provided for air purging of the pressure means and including an hydraulic valve connected with an air supply pipe and having upper and lower open pipes connected with one another.
When the arrangement is designed in accordance with the present invention, it provides for purging the arrangement, thus preventing its blocking and reduction of its efficiency.
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself however will be best understood from the following description of a preferred embodiment which is accompanied by the following drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1a-1d are views showing an arrangement in accordance with the present embodiment in consecutive stages of its operation;
FIG. 2 is a view showing the inventive arrangement in accordance with the second embodiment of the present invention; and
FIG. 3 is a view showing a cycle diagram of operation of the inventive arrangement.
DESCRIPTION OF PREFERRED EMBODIMENTS
An arrangement for elevating liquids by the use of solar and/or wind energy in accordance with the present invention has a liquid supply pipe 1 with a lower end introducable into a liquid. The upper end of the supply pipe 1 is connected with a lower end of a delivery pipe 2 by an inclined pipe 3. The axes of these pipes are located in the same plane. The upper end of the supply pipe 1 is located higher than the lower end of the delivery pipe 2. The upper end of the supply pipe 1 also forms an air port. The upper end of the delivery pipe 2 forms a liquid discharge port.
A connecting part of the pipes 1 and 2 is connected by an air supply pipe 4 with an upper part of a heat-exchanger 5 which forms means for forming pressure differential between the air port and the liquid discharge port. Connecting pipes 6 and 7 connect the upper part of a container of the heat-exchanger and the lower part of the same with purging means which include first and second identical hydraulic valves. Each hydraulic valve includes an upper pipe 8,9 and a lower pipe 10,11 respectively, located vertically and connected with one another by horizontal or inclined connecting pipes 12 and 13 respectively. Lower ends of the pipes 1,10 and 11 are provided cross section limiting members 14,15,16 formed as pipe portions of a smaller cross section.
The second hydraulic valve and particularly the upper end of its pipe 9 is connected via a pivot joint 17 and a bend 18 with a funnel-shaped diffuser 19. A wind vane 20 is connected with the diffuser 19 for driving the diffuser.
In accordance with another embodiment of the invention shown in FIG. 2, an additional container 21 with liquid is provided. It is located higher than the container of the heat-exchanger 5. The first hydraulic valve including the pipes 8,10,12 and a cross section limiting member 15, is accommodated in the container 21.
The arrangement in accordance with the present invention operates in the following manner.
The arrangement is immersed into a liquid to be elevated, for example water, to such a level that the inclined pipe 3 and the pipes 12 and 13 are of the hydraulic valves are immersed in the liquid. The liquid passes through the cross section limiting members 14,15, 16 and fill the pipes 1,3,10,12,11 and 13 as shown in FIG. 1a. As a result of this, the heat exchanger is isolated from the surroundings. The condition of FIG. 1a corresponds to the condition in point A on the diagram of thermodynamic condition of FIG. 3, at which the air pressure inside the heat exchanger 5 equals to the outside atmospheric pressure. The liquid level in the pipes 2,8,9 coincides with the liquid level in a reservoir with liquid to be elevated.
As a result of heating of air in the heat exchanger uner the action of solar energy or another source, the air pressure in it increases and air displaces the liquid from the inclined pipe 3 into the delivery pipe 2, from the upper part of the supply pipe 1 into its lower part, and from the lower part of the supply pipe 1 through the cross section limiting member 14 into the reservoir of liquid. Analogous processes take place in the hydraulic valves. The sizes of the respective parts of the arrangement are selected so that the height of a cut-off liquid portion in the delivery pipe 2 is smaller than the height of the supply pipe 1, and the quantity of liquid which is cut-off by air bubbles in each hydraulic valve is sufficient for formation in each of the vertical pipes 8 and 9 of liquid portions which are higher that the cut-off portions of liquid in the delivery pipe 2, and the quantity of air supplied from the heat-exchanger 5 into the pipes 1,3,10, 12,11 and 13 and required for displacing of the respective liquid portions into the pipes 2,8,9 has a considerably smaller volume than the total volume of air in the heat-exchanger 5.
Because of this, after formation of a liquid portion in the delivery pipe 2, increase of the height of liquid column in the pipes 8 and 9 will finish. Thus the process of formation of liquid portions in the pipes 2,8 and 9 takes place with a practically constant volume, and heating of air in the heat-exchanger by solar energy (or other energy) takes place in the transition AB in the diagram of FIG. 3. Thermodynamic condition in the point A corresponds to the system condition shown in FIG. 1a, and thermodynamic condition in the point B corresponds to the system condition shown in FIG. 1b. Actual values of the levels of lowering of liquid in the pipes 1,10 and 11 and values of height of elevating of the liquid portions in the pipes 8,9 of the hydraulic valves are determined not only by hydrostatic pressure of the formed liquid portion in the pipe 2, but also by value of dynamic pressure P 1 in FIG. 3 of air required for displacement of a liquid portion upwardly through the pipe 2 with overcoming of resistance in the latter.
Further absorption of energy by the heat-exchanger 5 leads to expansion of air in the latter with a constant temperature and pressure, isotherm-isobar BC in FIG. 3 and consists of expansion of air and energy consumption to displace the cut-off liquid portion upwardly through the pipe 2, as shown in FIG. 1c. Further supply of energy through the heat exchanger leads to throwing of the elevated liquid portion through the upper opening of the pipe 2, which is point C in the diagram of FIG. 3. Discharge of the liquid portion through the upper opening of the pipe 2 leads to loss of hermetization of the system, drop of pressure in the system to the atmospheric pressure and discharge of a portion of air from the heat-exchanger into surroundings, flowing of the liquid from the pipes 8 and 12 into the pipe 10 and from the pipes 9 and 13 into the pipe 11. Since the value of liquid columns in the pipes 8 and 9 is equal to the value of depth of lowering of the liquid level in the pipes 10 and 11 reached by the time before discharge of liquid through the upper opening of the pipe 2, and the cross sectional areas of the pipes 10 and 11 are greater than the cross sectional areas of the pipes 8,12 and 9,13, the volumes of liquid in the pipes 8,12 and 9,13 will be smaller than the volume of air in the pipes 10 and 11. The liquid which has been flown out from the pipes 8,12 and 9,13 does not fill liquid-free spaces in the pipes 10 and 11 and as a result of this the hydraulic valves will be temporarily open as shown in FIG. 1d.
As a result of discharge of the elevated liquid portion through the upper opening of the pipe 2, adiabatic expansion of air and decrease of its temperature take place in the heat exchanger. However, this process is not sufficient for returning the system to its initial condition identified by point A in the diagram of FIG. 3. and in FIG. 1a. From the time moment of complete discharge of the elevated liquid portion from the delivery pipe 2 and flowing off of the liquid from the pipes 8,12 and 9,13 respectively into the pipes 10 and 11, and till the time moment of filling of the pipes 1,3,10,12,11 and 13 with liquid, the system remains without hermetization. With the aid of wind, through the funnel-shaped diffuser 19, the bend 18 and the pipes 9,13,7,4,6,12,8,3 and 2, purging by air of the interior of the heat-exchanger takes place, as shown in FIG. 1d. The cross section limiting members 14,15 and 16 are needed for providing a required time interval between the above described time moments of the beginning and the end of hermetization loss of the system, and therefore of purging.
During filling of the pipes 3,12 and 13, the initial condition of the system and its readiness for performing a new cycle of liquid elevation is restored. The arrangement can operate even without the first hydraulic valve formed by the pipes 8,10 and 12 and connnected with the arrangement by the pipe 6. However, in the process of elevation of liquid through the delivery pipe 2 and after discharge of the liquid throught its upper opening, flowing out of a portion of liquid from the walls of the deliver pipe into the inclined pipe 3 takes place with the reduction of the cross section of the latter. This decreases the efficiency of purging of the heat-exchanger. The provision of the first hydraulic valve increases the efficiency of purging of the heat-exchanger and provides for a possibility to increase the output of the arrangement.
Work A performed by the arrangement during one cycle of liquid elevation is ##EQU1## wherein: P 2 is a pressure of air in the system during movement of a portion of cut-off liquid upwardly in the delivery pipe 2; and
V 1 -V o is an inner volume of the delivery pipe.
Contrary to the known arrangements, the height of liquid elevation in the inventive arrangement is determined not by a temperature difference between a heater and a cooler, but by a volume of liquid of the heat-exchanger. This makes possible to elevate liquid to any height with small temperature differences. The operation of the inventive arrangement can be compared with the operation of a steam engine or a two-cycle engine. The process of heating of a working medium, for example water, in a steam engine corresponds to the process of formation of the liquid portions in the pipes 2,8 and 9 and takes place in accordance with an isochore AB (FIG.3). The process of conversion during which a formed steam fills the working cylinder and displaces a piston in a steam engine corresponds to the process of displacement of the cut off liquid portion upwardly through the pipe 2. This work is a work of filling and it takes place in accordance with the isotherm-isobar BC of FIG.3. The subsequent process in the inventive arrangement takes place analogously to the processes which take place in the two-cycle internal combustion engine. During a working stroke of this engine, a piston is displaced by expanding combustion products and reaches a discharge slot through which the gases discharge from the cylinder. This corresponds in the inventive arrangement to flowing out of a portion of air from the heat-exchanger through the upper opening of the delivery pipe 2 during subsequent time after discharge of the elevated liquid portion. In the two-stroke combustion engine, after dischargae of the gases, air compressed in the crank chamber during the working stroke purges the cylinder through the purging window. Analogous process takes place in the inventive arrangement, in which purging of the interior of the heat-exchanger takes place under the action of wind through the upper end of the upper pipe 8 (purging window) of the first hydraulic valve and the open end of the delivery pipe 2. With the aid of the wind vane 20, the funnel-shaped member 19 is oriented with its open end in accordance with the direction of wind.
In the embodiment shown in FIG. 2, the first hydraulic valve including the pipes 8,12 and 10 is located higher than the upper part of the heat-exchanger and accommodated in the container 21 filled with liquid. The operation of this arrangement is similar to the operation of the arrangment of FIG. 1. The difference, however, is that in the event of a weak wind or its absence, purging of the heat-exchanger takes place because of the difference in densities of heated air in the heat-exchanger and the denser surrounding air. The denser air is supplied through the second hydraulic valve into the lower part of the heat-exchanger and displace the heated air from the upper part of the latter through the first hydraulic valve located above the heat-exchanger.
For increasing the efficiency of the arrangement, greenhouse effect can be utilized. The heat-exchanger can be accommodated in a case which is transparent for solar radiation and not transparent for long=wave radiation, for example of glass or transparent plastic. For increasing the dependency of operation of the arrangment from wind strength, the height of the heat-exchanger is to be increased.
The invention is not limited to the details shown since various modifications and structural changes are possible without departing in any way from the spirit of the invention.
What is desired to be protected by Letters Patent is set forth in particular in the appended claims. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. provisional application Serial No. 60,132,207 filed May 3, 1999.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention is flexible pipe for conducting petroleum or other fluids subsea or on land and the method of forming same.
2. Description of the Related Art
Conventional bonded flexible pipe is described in American Petroleum Institute document API Specification 17 J. These types of pipe are typically used for both “sweet” and “sour” service production, including export and injection services. Fluids transported include oil, gas, water and injection chemicals and gas. A typical construction is made up of a plurality of tubular layers, starting with an interlocking metal carcass and followed by a liner tube of plastic to retain the fluid within the pipe. Hoop strength armor reinforcement in the hoop direction is provided by helical metal wires which may be in several layers and wound in opposite helical directions. Additional layers may also be used, with a final jacket extrusion to complete the assembly, with a tough wear resistant material.
U.S. Pat. Nos. 5,261,462 and 5,435,867, both issued to Donald H. Wolfe, et al., are examples of tubular composite pipe in the prior art. Those patents relate to tubular structures having a plastic tube for the fluid conductor, which has an outer layer formed form alternating spirally wound strips of composite and elastomer. It is believed that the prior art composite pipes, such as disclosed in the above patents, have been limited to relatively short commercial lengths, by reason of the method by which such tubular structures have been made.
Typically, composite flexible pipes are made by filament winding, which involves turning the pipe while feeding and moving resin impregnated fibers from bobbins back and forth along the length of the pipe. Such technique limits the length of the reinforced flexible pipe which can be manufactured because of the number of bobbins required for the large number of fibers that are used in each pass. As a practical matter, it was not known how to make relatively long lengths of composite pipe sufficient for subsea use because of such problem.
In single bobbin machines, unloading and reloading time is a function of the time taken to thread each end of the fibers, the number of bobbins, and the time required to replace each bobbin. Also, due to the material payload requirements, a single bobbin-type machine will require each end to travel some distance from its bobbin over rollers, sheaves, eyelets, etc., through the machine to the closing point on the pipe, thus creating a time-consuming task. Because of the hundreds, and even thousands of bobbins, extremely large machines would be required to make a composite reinforced pipe in long lengths by such prior art techniques, consequently, the industry has not had available composite flexible pipes in long lengths suitable for subsea production and well operations. Multiple fiber tows are also not practical for long pipe lengths because of the fiber loading times required.
SUMMARY OF THE INVENTION
With the present invention, discrete tapes are first formed from the fibers and resin or the like, so that the tapes are wound on spools which reduces the number of bobbins required as compared to the number of bobbins required for single fiber filaments, whereby it is possible to manufacture long lengths of composite flexible pipe. The tapes are initially formed and then are fed from tape spools rather than the fiber bobbins in the prior art. Also, each tape is composed of a plurality of superimposed thin tape strips formed of predominantly, unidirectional fibers, which are impregnated with an epoxy or other suitable bonding resin which cures with heat, cold, ultraviolet (UV) or other curing methods. The multi-layer tapes are wrapped with a polyethylene or similar plastic or thin metallic strip or covered by thermoplastic extrusion to confine them as a unit together, with bonding adhesive between the tape strips being prevented from escaping from the wrap. Each tape thus made is fed from a tape spool to the tubular core as the tubular core is rotated, or as the spools are rotated relative to the core, which produces helical wraps of each of the tapes on the tubular core in the same or opposite helical directions for reinforcement of the core.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a typical fiber arrangement for the tape of this invention;
FIG. 2 is a view of the fibers of FIG. 1 embedded in a resin such as an epoxy resin;
FIG. 3 is a cross sectional view of the final tape which has a plurality of fiber tapes laminated together with a thermoplastic or elastomeric material to form a composite tape as a unit;
FIG. 4 is a schematic illustration of a method of this invention showing the method and apparatus for making the resin impregnated fiber tapes of this invention; and
FIG. 5 is an isometric view of a pipe made in accordance with this invention, showing the arrangement of the tapes helically wound on the fluid conducting core or tube.
DETAILED DESCRIPTION OF INVENTION
Referring now to FIG. 1, a preassembled fiber tape strip is shown which is formed of a plurality of fibers 11 which extend parallel to each other in the warp direction which is the main direction of the tape. Those fibers are made of fiber glass, Kevlar, carbon or similar materials. Fibers 12 are disposed perpendicular to the fibers 11 and extend underneath them and typically are joined together with a stitch in the manufacturing and assembly process. Such fibers 12 are in the weft direction across the tape strip. Preferably, the majority strength of the tape strip is provided in the direction of the fibers 11 , and in some instances each strip of tape may be formed solely of warp fibers 11 . Also, strips of thin metal of steel, aluminum, or other metal, some being perforated, may be used between or outside of the fiber strips in each laminate 15 .
The fiber matrix formed of the fibers 11 and 12 may be separately formed and thereafter impregnated with a resin such as an epoxy resin, or the fiber matrix may be made on the same machine that impregnates such fibers with the resin.
FIG. 2 is an illustration of the tape strip T of this invention, one form of which is made by impregnating the fibers 11 and 12 with an epoxy resin or the like to form a single laminate 15 . The laminates need to be as thin as possible to reduce strain in them when they are bent onto a pipe surface. Typically, the thickness of each laminate layer is from about 0.010″ to about 0.030″. This is somewhat of a trade-off between (a) very thin tape which provides for very efficient but long production process, and (b) a thicker tape which is less efficient (more strain) but requires less production time.
Each laminate 15 which is formed by this invention is a separate tape T. A plurality of such tapes T are superimposed on each other as shown in FIG. 3 and, as will be explained, are bonded together by an adhesive which may initially be an uncured epoxy or resin between the tapes T which is later cured during or after the tapes A are wrapped on the core C. Once the adhesive between the tapes cures, the overall laminate product A assumes the radius to which it was bent. This happens because the tapes 15 slide over each other, and then when the adhesive cures, they cannot slide.
In FIG. 3, the finished tape A is shown in cross-section schematically with the warp fibers 11 exposed at the ends, and the epoxy impregnating and bonding the multiple tapes into the final tape T. The weft fibers are not shown in FIG. 3 because they extend across FIG. 3 just behind the cut line for FIG. 3 .
An external protective jacket 20 of nylon, polyethylene, or similar flexible thermoplastic or elastomeric material surrounds the superimposed tapes T and encloses the adhesive between such tapes T so that none of the uncured adhesive escapes from the jacket 20 during curing.
A typical arrangement for forming the final tape A shown in FIG. 3 is illustrated by the equipment schematically shown in FIG. 4 .
By way of example, the laminates 15 or tapes T are arranged in a superimposed relationship and are fed through squeeze rollers 25 . Prior to reaching the squeeze rollers 25 , the tapes T are spaced apart so that adhesive in the form of a resin or the like is applied between the tapes T with any suitable type of applicator 27 or spray which supplies adhesive or resin from an injector 28 and header 29 suitably connected to the applicator 27 .
Guide rollers 35 serve to maintain the tapes T in a superimposed alignment with each other.
Finally, a rotatable spool 37 which has a wrapping strip 39 of polyethylene, nylon or similar flexible thermoplastic or elastomeric material thereon is positioned for feeding a helical wrap of the strip 39 to form a protective jacket 20 by rotating the spool head 37 . Such protective jacket 20 is thus formed by the tape 39 being wrapped about the tapes T to form the final multitape product A shown in cross-section in FIG. 3 . Instead of the helical wraps 39 , a “cigarette” wrap may be formed by a longitudinal strip that extends lengthwise of the tape T, and which is folded to partially or fully extend around or substantially around the tape T. The helical wrap 39 preferably may then be wrapped outside of the cigarette wrap to complete product A.
Referring now to FIG. 5, a simple pipe construction is illustrated for showing the use of the tape A for reinforcing an inner core or tube C which is formed of a flexible fluid conducting material such as flexible polyethylene or metal which is thick enough to have some rigidity but thin enough to still be flexible without significant deformation or collapse. An anti-abrasive layer B of relatively thin polyethylene or the like is preferably disposed between the helical wraps of the tapes A to provide for anti-abrasion between two layers of the helical wraps. Although the wraps of the tapes A are shown as opposite helical wraps, the invention is not limited thereto. For example, the construction may have two or more wraps with a left hand lay, and two or more with a right hand lay, and then two or more with a left hand lay.
It is noted that the tapes A are in a non-bonding relationship to the core or tube C and to each other so that when the core or tube C flexes during use, the tapes A may slide to a limited extent relative to the core or tube C and to each other to permit the flexing of the entire assembly. Additionally, it is noted that there are small gaps or helical spaces 40 between each of the tapes A to provide for limited relative movement of the tapes A with respect to the core or tube C and to each other for flexibility when the core or tube C is flexed.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the details of the illustrated apparatus and construction and method of operation may be made without departing from the spirit of the invention. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to Josephson tunneling storage devices for use in DRO (Destructive Read Out) random access memory arrays. More specifically, it relates to Josephson tunneling devices which are capable of storing binary information in the form of a single flux quantum. Still more specifically, it relates to single flux quantum Josephson tunneling storage devices which are capable of storing a single flux quantum in the absence of applied bias or at zero applied field. Still more specifically, it relates to a single flux quantum Josephson tunneling storage device in which writing and sensing is performed with coincident currents. Each device during sensing acts as its own sense detector and is capable of switching to the voltage state if a flux quantum is stored. The ability to store a single flux quantum at zero bias is determined by controlling the Josephson current density profile across the junction which, in turn, permits the storing of binary information without the need for external loops or circuits which normally carry circulating currents. Sensing uses the fact that the gain characteristics of the junction have their switching thresholds extended by increasing the junction resistance across the entire Josephson junction. The use of such single flux quantum storage devices permits the fabrication of very high density arrays having extremely fast switching times which require no ultrahigh sensitivity circuits to sense a stored signal.
2. Description of the Prior Art
The principle of Josephson current devices is understood in the prior art, and such devices have been proposed for memory applications. In particular, reference is made to U.S. Pat. No. 3,626,391 issued Dec. 7, 1971, in the name of W. Anacker and assigned to the same assignee as the present invention. In that patent, a memory array is described which includes a plurality of Josephson tunneling devices wherein each memory cell is comprised of two such Josephson devices. The state of each memory cell is determined by the direction of the circulating current in the cell.
In two technical papers, a superconducting ring containing a barrier such as a Josephson junction is studied. In particular, the reaction of superconducting rings having weak links therein to the application of external magnetic fields has been reported by F. Block in a paper entitled "Simple Interpretation of the Josephson Effect", which appears in Physical Review Letters, Vol. 21, No. 17, Oct. 21, 1968 on page 241. The paper discusses the Josephson effect in terms of a superconducting ring wherein the ring is linked with an external magnetic field. In another article by D. E. McCumber appearing in Journal of Applied Physics, Vol. 39, No. 6, May 1968, page 2503, superconductor weak link junctions and the effect of magnetic fields on these junctions is discussed. On page 2507 of this article, McCumber describes a superconducting loop containing a single weak link and mentions that this configuration has potential utility as a memory element.
U.S. Pat. No. 3,705,393 issued Dec. 5, 1972, in the names of W. Anacker and H. H. Zappe and assigned to the same assignee as the present invention, describes a superconducting memory array wherein the memory cells are superconducting rings each of which has at least one element therein capable of supporting Josephson tunneling current. In the patent, coincident currents are used to trap flux in the rings and to release the trapped flux for readout of the memory cells. Fast operation and tolerable limits on drive currents are indicated as being obtainable if single flux quantum operation is utilized. To achieve single flux quantum operation, the capacitance, inductance, and damping of each memory cell must be within certain limits.
In 1970, P. W. Anderson, in an article in Physics Today, Vol. 23, page 29 (1970), described a flux shuttle which is a single vortex shift register. The first experimental results on the flux shuttle were recently reported by T. A. Fulton and L. N. Dunkelberger in an article in Applied Physics Letters, Vol. 22, page 232 (1973). In the devices of the articles and the last mentioned patent, flux is stored either in small superconductive inductances in the form of loops containing one Josephson junction or in single rectangular junctions which require an external bias field. Reading is performed by sensing the signal induced into the array lines during the release of the trapped fluxoid. Although very high packing densities are possible with such schemes, their disadvantage is that the energy released for reading is of the order of only 10 - 18 joules. Also, since the fabrication of the prior art arrangements are relatively large due to the requirement for loops, such arrangements do not provide the ultimate in small size, high speed devices which is the direction towards which most present-day technologies are tending. In addition, none of the known arrangements provide a device which is its own sense detector switching the device to the gap voltage if a flux quantum is stored.
SUMMARY OF THE INVENTION
A Josephson junction device for storing at least a single flux quantum in the absence of an external magnetic field, in its broadest aspect, comprises first and second superconductive elements disposed in an x, y plane; an insulation layer of thickness sufficient to permit Josephson tunneling disposed between the elements and, means integral with at least one of said elements and said layer for generating a current density profile defined by ##EQU2## where x is the length dimension, and y is the width dimension, such that the profile J 1 (x) has a larger magnitude at the boundary portions of said device than at the center portion of said device.
In accordance with the broadest aspects of the invention, a Josephson junction device is provided which includes means integral with said device for increasing the junction resistance of the device to reduce the damping of the device.
In accordance with the broader aspects of the invention, a Josephson junction device is provided which includes means disposed in electrically coupled relationship for writing information stored in the device first mentioned hereinabove and for writing and reading in the device having reduced damping.
In accordance with broader aspects of the present invention, the means for generating the current density profile includes a portion of each of the superconductive elements disposed in overlapping relationship, at least a portion of the extremity of at least one of the superconductive elements extending toward the other to provide a narrower tunneling region at the center of the device than at the boundaries of the device.
In accordance with still broader aspects of the present invention, the means for increasing the Josephson junction resistance includes the insulation layer of the device all portions of which are of a thickness greater than the first mentioned thickness; the greater thickness being such that Josephson tunneling occurs along the length of said junction in accordance with J 1 (x) but is of decreased magnitude everywhere along the length of the junction.
In accordance with more particular aspects of the present invention, said at least a portion of the extremity of at least one of said elements extending toward the other forms a tapered notch, a rectilinear notch or a curvilinear notch.
In accordance with more specific aspects of the present invention, the means for reading the device of reduced damping includes means connected to the device and the control element for switching said device to the voltage state for one stored binary condition and for maintaining said device in an unchanged state for another stored binary condition.
In accordance with still more specific aspects of the present invention, a Josephson junction device for storing a single flux quantum in the absence of an external magnetic field is provided which comprises an interferometer device which includes at least two spaced apart Josephson junctions each of which is capable of supporting tunneling via an insulation layer of thickness sufficient to support tunneling. The device has a current density profile defined by ##EQU3## such that the profile J 1 (x) has a given magnitude at the spaced apart junctions and zero magnitude between the spaced apart junctions. Further included is means integral with the device for increasing the junction resistance of the Josephson junctions to reduce the damping of said device.
In accordance with still more specific aspects of the present invention, the means for increasing the junction resistance includes an insulation layer of thickness greater than the above mentioned thickness; the greater thickness being such that Josephson tunneling occurs in accordance with J 1 (x) but is of decreased magnitude through the Josephson junctions. Writing and reading means are also provided for storing and recovering information from the above mentioned interferometer arrangement.
It is, therefore, an object of this invention to provide a single flux quantum storage device which is capable of storing at least a single flux quantum at zero bias.
Another object is to provide a single flux quantum storage device in which the Josephson current density is reduced by providing higher junction resistance and, therefore, lower damping.
Another object is to provide a Josephson junction memory element which does not require an associated superconducting loop for storage.
Still another object is to provide a memory array having very low power dissipation and very high speed switching operation.
Still another object is to provide a single flux quantum storage element which acts as its own sense detector and switches to the voltage state if a flux quantum is stored upon the application of coincident currents.
The foregoing and other objects, features and advantages of the invention will become apparent from the following more particular description of the preferred embodiment of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional view of a device in accordance with the teaching of the present invention which is capable of storing a single flux quantum at zero bias. The device shown has a single rectangular Josephson junction having an insulator disposed between superconductive elements wherein the insulator is of such thickness that it is capable of supporting Josephson tunneling along the length of the junction.
FIG. 2A is a plan view of a Josephson junction device in accordance with the teaching of the present invention wherein a desired Josephson current density profile J 1 (x) is provided by causing the extremities of the superconductive elements to extend toward each other in the form of rectilinear notches. Broadly speaking, the figure shows a centrally disposed necked down region which provides a Josephson current density profile which has a larger magnitude at the boundary portions of the device than at the center portion of said device.
FIG. 2B is a graphical representation of the Josephson current density profile, J 1 (x), along the length of the Josephson junction obtained using the configuration shown in FIG. 2A.
FIG. 3A is a plan view of a Josephson junction device which provides a Josephson current density profile in accordance with the teachings of the present invention by forming tapered notches in the superconductive elements which form the Josephson junction device.
FIG. 3B is a graphical representation of the Josephson current density profile obtained using the tapered notch arrangement of FIG. 3A.
FIG. 4A is a plan view of a Josephson device in accordance with the teaching of the present invention wherein the extremities of the superconducting elements extend toward each other in such a way as to form a curvilinear notch or "dumbbell" shaped junction.
FIG. 4B shows the Josephson current density profile obtained utilizing the arrangement of FIG. 4A.
FIG. 5 is a graphical representation of a set of threshold curves of gate current (I g ) versus control current (I c ) both normalized to (I 0 ) for a device similar to that shown in FIG. 1 with the exception that the curves represent a device having low junction resistance (R j ) which results in a device having large damping. Switching to the voltage state occurs if the applied currents cross a solid line segment of the curves. Also, a change from one quantum state to another occurs if the applied currents cross a dashed line segment of the curves.
FIG. 6 is a graphical representation of a set of computed curves similar to that shown in FIG. 2 except that the curves show the (I g ) versus (I c ) characteristic normalized to (I 0 ) for a device having a high junction resistance (R j ) which results in a device having low damping. It is significant to note that the curves of FIG. 6 have their switching thresholds extended for all vortex states as a result of the increase in junction resistance.
FIG. 7 shows a graphical representation of the (I g ) versus (I c ) characteristic for a device similar to that shown in FIG. 4A and further indicates writing and reading of the device by the application of coincident currents. The effect of reduced damping extends the gain characteristics of the modes shown to the extent that reading of both binary ones and binary zeros can be carried out unambiguously by coincident current selection. The solid line segments represent the switching threshold boundary while the dashed line segments represent the quantum state boundaries.
FIG. 8 shows an array of Josephson junction devices capable of storing a single flux quantum and providing low damping similar to that shown in FIG. 4A which are written and read by coincident current selection via word and bit lines.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown therein a partial cross-sectional view of a rectangular Josephson junction device 1 which is capable of storing a single flux quantum at zero bias or in the absence of an externally applied magnetic field. Josephson junction device 1 consists of superconducting elements 2,3 which are spaced apart by a dielectric or insulator 4 which has a thickness across the device which permits tunneling therethrough. Superconducting elements 2,3 may be formed of any superconductive material well known to those skilled in the cryogenic arts, such as lead, niobium, tin or aluminum. Dielectric 4 may also be formed from any dielectric or insulator well known to those skilled in the cryogenic arts such as silicon dioxide or oxide of the metal being used and, as indicated hereinabove, its thickness should not be so great as to prevent Josephson tunneling therethrough. A control line 5 which is disposed in orthogonal, overlying relationship and spaced from superconducting element 1 by an insulator (not shown) provides control current (I c ) which, in combination with current applied to elements 2,3 stores or reads out information held in device 1 in the form of current vortices or a zero current vortex. Thus, currents (I c ) and (I g ) are coincidentally applied to control line 5 and superconductive elements 2,3 to both write and read information into and from device 1. In FIG. 1, (I g ) may be applied to superconductive element 2 in a direction indicated by circled cross 6 which is also the direction of applied magnetic field due to current flow in control line 5.
Current vortices can be formed inside long Josephson junctions by applying an external magnetic field of the order of or larger than I m (0). However, these vortices are not stable in zero magnetic field. The reason is that the Lorentz force resulting from the self-field of a vortex pushes the circulating Josephson currents outward.
To maintain a stable vortex inside a device similar to that shown in FIG. 1, the energy associated with the (inductive) Josephson current must be larger at the junction edges than the energy resulting from the Lorentz force. This can be accomplished by increasing the Josephson threshold current at two opposing junction ends by locally increasing the Josephson current density or by providing greater junction widths at the opposing junction ends than at the center. This latter approach will be discussed hereinbelow in more detail in conjunction with FIGS. 2A, 3A and 4A. In any event, the Josephson current density profile is such that it has a greater magnitude at the boundaries of device 1 than at the center of device 1. One way of achieving the desired Josephson current density profile is shown in FIG. 1. Thus, insulation 4 is thinner at the ends 7,8 of device 1 than at centrally disposed region 9. In this way, device 1 is a device with a single rectangular Josephson tunneling junction having a dielectric or insulator 4 disposed between superconductive elements 2,3 which supports Josephson tunneling along the length of the junction. It should be appreciated that, under such circumstances, the device of FIG. 1 is distinguishable over the known interferometer devices which consist of a pair of Josephson tunneling junctions. By providing a higher current density at the ends of a single Josephson junction device which is generally represented by ##EQU4## and having a greater current density at the boundaries than at the center of the device, current vortices corresponding to a single flux quantum can be entered into device 1 of FIG. 1 by a suitable combination of gate current (I g ) and control current (I c ). The magnetic field necessary to generate a vortex is produced by control line 5. The device current which opposes the penetration of the external control field ultimately forms the vortex shown by the dashed arrow 10 in FIG. 1. Thus, when a vortex is formed in device 1 of FIG. 1, it remains stable in the absence of an external magnetic field whereas, in the prior art single junction devices, an external bias or magnetic field was required to maintain the current vortices formed in a stable state.
The Josephson current density profile mentioned hereinabove may be provided in other ways than by controlling the thickness of dielectric layer 4 at the boundaries of device 1. Thus, the end portions 7,8 of device 1 which contain the boundary portions of superconductive elements 2,3 may also be utilized to provide the desired current density profile. Under such circumstances, device 1 of FIG. 1 has a dielectric or insulator 4 of uniform thickness while the boundary portions of superconductor elements 2,3 at ends 7,8 utilize a metal having a different work function from the metal utilized for the portions of superconducting elements 2,3 in centrally disposed region 9. Specifically, the work function of the metal at the boundary portions of device 1 is lower than the work function of that portion of conductors 2,3 associated with centrally disposed region 9. By lowering the work function of those portions of superconductive elements 2,3 associated with end regions 7,8, a Josephson current density distribution is obtained which has a greater magnitude in those portions of device 1 associated with end regions 7,8 than in those portions of device 1 associated with centrally disposed region 9. Thus, where centrally disposed region 9 is made of lead, regions 7,8 may be fabricated from a lower work function metal such as tin. The resulting device has the desired Josephson current density profile, fulfills the criterion of being a single Josephson junction device and requires no external bias or magnetic field to maintain a stored single flux quantum in a stable condition.
The criterion that a Josephson junction device exhibit a Josephson current density profile such that the profile has a larger magnitude at the boundary portions of the device than at the center portion of the device can be achieved with uniform dielectric thickness and single work function metals by shaping the junctions. Stated another way, the desired Josephson current density profile may be generated by causing at least a portion of the extremity of at least one of the elements 2,3 which are disposed in overlapping relationship to extend toward the other to provide a narrower tunneling region at the center of device 1 than at the boundaries of device 1. FIGS. 2A-4A show plan views of such structures which provide desired Josephson current density profiles as shown in FIGS. 2B-4B, respectively. Referring now to FIG. 2A, there is shown therein a plan view of a single Josephson junction device 1 wherein a portion of the extremity of each of the elements 2,3 extends toward the other to form a rectilinear notch 11 in each of the superconductive elements 2,3. In FIG. 2A, it should be appreciated that a dielectric or insulator 4, although not shown, is disposed between elements 2,3 at their places of overlap. As can be seen from a consideration of FIG. 2B, which shows the Josephson current density profile along the length of the Josephson junction of device 1 or in the x direction, device 1 has a Josephson current density profile J 1 (x), which has a greater magnitude at the boundaries of device 1 than at the center of device 1.
Similarly, in FIGS. 3A and 4A, which show tapered notches 12 and curvilinear notches 13, respectively, in the extremities of superconducting elements 2,3, their Josephson current density profiles J 1 (x), also have greater magnitudes at the boundary portions of device 1 than at the center portions of device 1. As with device 1 of FIG. 2A, devices 1 of FIGS. 3A, 4A also have dielectrics or insulators disposed between elements 2,3 at their places of overlap. Each of the devices just described has the desired Josephson current density profile as a result of what may be generally described as a centrally disposed necked-down region. Thus, as a general rule, the shape of the Josephson junction may take any form provided the resulting structure has a centrally disposed necked-down region. It should be appreciated, at this point, that it is not necessary to have both of the extremities of superconducting elements 2,3 extend toward each other to form the centrally disposed necked-down region but that only one of the extremities of conductors 2,3 need extend toward the other extremity. Thus, in FIG. 2A, rectilinear notch 11 in element 3 may be eliminated without changing the ultimate Josephson current density profile. The only change required is to have notch 11 of element 2 extend in the y direction until it substantially overlaps the extremity of the now unnotched element 3. Similarly, in the tapered and curvilinear notch embodiments of FIG. 3A and FIG. 4A, respectively, only one of the elements 2,3 need have the tapered notch 12 or curvilinear notch 13. With respect to FIGS. 2A-4A, it should be appreciated that in actual operation a control line 5 is disposed over each of the Josephson junctions shown which, when a control current, I c , is applied, provides a magnetic field in the direction shown by the arrow in each of the FIGS. 2A-4A. In all of the embodiments shown, dielectric or insulator 4 need only have a minimum thickness which is sufficient to support Josephson tunneling along the length of the junction. Adhering to this criterion in combination with the other parameters described hereinabove permits the generation of the desired Josephson current density profile and the resulting devices are capable of storing a single flux quantum in the absence of an externally applied magnetic field or at zero bias.
Using the devices shown in FIGS. 1 and 2A-4A, a threshold characteristic having the general form of that shown in FIG. 5 can be obtained by plotting the variation of gate current, (I g ), with respect to control current, (I c ). In FIG. 5, each of the parameters (I g ), (I c ) is plotted normalized with respect to (I 0 ). In FIG. 5, the zero vortex curve which relates to a device having low junction resistance, R j , and therefore, large damping, is disposed symmetrically about the I g /I 0 axis and having values of ±1.5 or I c /I O when I g is 0. Thus, for a device not containing a vortex any combination of control current, (I c ), and gate current, (I g ), which remain inside the zero vortex curve, no vortex can be formed in the devices described hereinabove. If the combination of these currents is such that the operating point of the device is brought outside the heavy line portion of the zero vortex curve, the device switches from the superconducting state to the voltage state in the usual manner of Josephson junction devices. Also, if the combination of applied currents shifts the operating point of the associated device so that it crosses a dashed portion of the zero vortex curve, the device stores a plus or minus vortex. Under such circumstances, a Josephson junction device is capable of storing a single flux quantum which may have one of two possible current vortex directions as indicated by the references in FIG. 5 to plus (+) vortex and minus (-) vortex. Once a device has changed from one vortex mode to another, the vortex mode from which the device has changed no longer exists and, accordingly, its threshold characteristic in that mode no longer exists. Thus, in FIG. 5, if the combination of currents applied changes the device operating point from a zero vortex mode to a plus vortex mode by crossing the dashed line of the zero vortex mode, the zero vortex mode disappears and only the plus vortex threshold characteristic exists. As long as the combination of currents applied remains within the plus vortex mode threshold characteristic, the associated device is capable of storing a single flux quantum. Where the combination of currents applied causes the heavy line portion of any of the vortex modes to be crossed, the associated device switches into the voltage state. Also, if the combination of currents applied to the device when it is storing a single flux quantum is such that the dashed line portion of the plus vortex mode threshold characteristic is crossed, the device changes from a plus vortex mode back to the zero vortex mode and, a single flux quantum can no longer be stored. From the foregoing, it should be clear that combinations of gate and control currents can be applied to a device such that the device will store either a zero or positive vortex which are representative of binary zero and binary one conditions, respectively. This can be achieved, in the usual case, by applying coincident gate and control currents of such a value that either a zero vortex or a positive vortex is stored in the associated device. When, however, the information stored is to be read, the application of coincident currents produces an output current in the gate line when a positive vortex is stored and no current when a zero or negative vortex is stored. For example, if a binary one is stored in the form of a positive vortex, the application of coincident currents causes the dashed line portion of the positive vortex curve to be crossed causing the release of the stored vortex and the operating point of device 1 to change to the zero vortex mode. The released vortex having an energy of the order of 10 -18 joules causes a small current pulse to be injected into the gate line associated with device 1. The same coincident currents applied when no vortex is stored produce no output since the dashed line portion of the zero vortex is not crossed. It should be recalled that when a zero vortex exists a positive vortex does not exist and vice versa.
Referring now to FIG. 6, there is shown therein threshold curves of I g /I O versus I c /I O similar to those shown in FIG. 5 except that the curves shown are those for a device which exhibits large R j and consequently lower damping. The result of increasing the junction resistance, R j , is to extend the heavy line portions of FIG. 5 such that the switching threshold of the device is extended as shown in FIG. 6. The extension of the switching threshold, as shown by the heavy lines in FIG. 6, when compared to the switching threshold of the device of FIG. 5, permits a crucial change in the operation of a device when it is being used as a memory element to store a single flux quantum at zero bias. This crucial change results from the extending of the switching thresholds of the device which is achieved by reducing the magnitude of the current density profile which, in turn, is achieved by providing a large junction resistance for a device having a desired current density profile. In FIG. 6, it should be noted that the critical point (that point where a combination of applied gate and control currents cause a device to switch into the voltage state) on the zero vortex curve is situated at I g /I O ˜ 0.9. As a result, if the threshold curve for a zero vortex or zero quantum state is crossed with gate current levels I g < 0.9 I O , a positive vortex is formed without switching into the voltage state. Of course, at gate currents greater than 0.9 I O , the device switches into the voltage state. In FIG. 6, it should also be noted that critical points on the positive and negative vortex threshold curves occur near I g /I O ˜ 0.4 so that switching to the voltage or 2Δ state occurs at lower gate current levels. Thus, in terms of storing a single flux quantum, the writing of such information is little affected since switching between vortex thresholds or quantum states is still all that is required to store a binary one, for example, in a positive vortex or single flux quantum state. However, the reading of a device which is storing, for example, a binary one in the form of a positive vortex or single flux quantum state is now radically changed. Recalling that the vortex threshold curves of FIG. 5 which represent a device with low junction resistance, R j , that reading unambiguously was achieved only by releasing a single flux quantum from the device by applying currents which crossed the positive vortex curve at a dashed line portion, it can be seen from a consideration of the threshold curves of FIG. 6 that reading a binary one which is stored in a device in the form of a single flux quantum can now be achieved by switching a device with low damping to the voltage state. Because of the extending of the switching thresholds, it is now possible using applied coincident gate and control currents to unambiguously detect the presence of either a binary one or a binary zero using the same values of coincident current to detect either state. FIG. 7 wherein the switching thresholds are superimposed on the vortex thresholds clearly shows the current conditions under which a device of low damping may be both written and read.
Referring now to FIG. 7, if a device represented by the curves of FIG. 7 is initially empty, a vortex will not be produced if the operating point remains inside the curve designated 0 vortex. For purposes of illustration, any combination of gate and control currents which are coincidentally applied to a device and its control line, respectively, which terminate in the shaded area 14 (otherwise identified as Write "0") may be utilized to write a binary zero. At this point, it should be appreciated that the curve designated -- vortex in FIG. 7 may be used instead of the curve designated 0 vortex to both write and read a binary condition such as a binary 0 using the same currents described hereinbelow in connection with the 0 vortex curve. The upper bound of gate current which can be applied is, of course, determined by critical point 15 on the positive vortex curve which would come into play when it is desired to change from a binary one state represented by the positive vortex curve to a binary zero state. By applying currents which cross the positive vortex threshold curve only at a dashed portion, this change of states can be achieved without switching to the voltage state. To write a binary one, gate and control currents may be applied which extend into shaded area 16 (otherwise identified as Write "1") without crossing the heavy line area of a threshold curve. Again, shaded area 16 has an upper value of gate current which is determined by critical point 17 which would come into play in changing from a zero vortex state to a positive vortex state. Obviously, a gate current greater than 0.9 causes the switching threshold of the zero vortex curve to be crossed and the device to be switched into the voltage state.
With respect to reading, it is, of course, well known that the same coincident currents must be applied and that an unambiguous signal must be obtained for one of the two possible states of the device being read. As has been indicated hereinabove, when a device has large damping, it is not possible to obtain such an unambiguous signal for one of the two possible states being stored in the device by switching into the voltage state. Control of the junction resistance, R j , to the extent that a device is provided with large junction resistance extends the switching threshold of such a device making it possible to obtain the desired unambiguous readout for a stored binary condition.
Again referring to FIG. 7, it should be clear that by applying the same values of gate and control currents an unambiguous switching to the voltage state can be obtained when a positive vortex is stored and no readout signal at all can be obtained using the same coincident currents when a zero vortex is stored. In FIG. 7, any combination of gate and control currents which brings the operating point of the device into shaded area 18 (otherwise labelled Read) causes the device to switch into the voltage 2Δ state if a positive vortex is stored. Where a positive vortex is not stored, the threshold curve for a positive vortex does not exist and the very same applied coincident currents do not cause a crossing of a switching threshold and no output is obtained since the operating point of the device remains within the zero vortex curve which is the only one which exists when a zero vortex is stored in the device. As in the case of a single Josephson junction, when the presence of a positive vortex is sensed by the switching of the device to the 2Δ or voltage state, the device remains in the voltage state as long as gate current is maintained. It should be appreciated that far more energy is available for sensing under these circumstances than when a single fluxoid was released using prior art reading approaches. Once all currents are removed from the device, the original information is lost, and the device may be in either of the three quantum states. Simulations and experimental results have shown that the limits of the switching threshold curves of FIG. 7 depend on device damping, which is, to the first order, determined by the low voltage single particle tunneling resistance, R j , of a junction. The curves of FIG. 7 correspond, as previously indicated, to a device having low damping wherein the junction resistance, R j , to provide the ability to read unambiguously should be ##EQU5## where L is the inductance of the device and C is the capacitance of the junction. Based on this relationship, it should be clear that the condition for the above read out scheme may also be controlled by changing either L or C. Thus, for substantially fixed values of L and C, a small decrease in the thickness of the dielectric between superconducting elements increases the junction resistance, R j . Also, for a fixed thickness of a dielectric between superconducting elements, a variation in L may be obtained by changing the depth of the notches shown in FIG. 2A-4A. The greater the depth of the notch, the greater is the constriction and the greater is the value of L. Another way to affect inductance is to change the superconductive penetration depth, λ, by changing the type of materials used, for example. In this instance the greater the penetration depth the greater is the inductance term L in the above relationship. The capacitance, C. may be changed by utilizing metals the oxides of which have larger dielectric constants, ε. In general, as long as the above indicated inequality is preserved, the switching threshold curves are extended and it is irrelevant which of the parameters involved is changed.
Experimental devices having a shaped tunneling junction similar to that shown in FIG. 3A have been fabricated. A Josephson tunnel junction is formed between two lead alloy superconductors. The junction formed by a curvilinear notch in the extremity of the lower superconductor delineates one side of the device while an insulation layer of silicon oxide about 4000 A thick having a corresponding curvilinear notch extending toward the first mentioned delineates the other side of the junction. The final device has the shape of a butterfly or dumbbell. The inductance L which is predominantly determined by the central necked-down or constricted region was estimated to be approximately 0.5pH. While the experimental device did not utilize an orthogonal bit line, it was equipped with two longitudinal control lines. The control current was produced by feeding equal but opposite currents through these control lines. In the experimental device, the screening currents induced on top of the upper superconductive element produced a small current through the constriction. The information stored at an energy level of approximately 3 × 10.sup. -18 joules showed remarkable stability despite unshielded conditions in a laboratory environment. Quasistatic writing and sensing with cycle times of 5 minutes have been demonstrated. The switching time of the present device is estimated to be 50ps. Writing was performed with triangular pulses having a base width approaching lns, and a sense cycle with similar pulses was also utilized.
Referring now to FIG. 8 a plan view of a portion of an array utilizing Josephson devices similar to that just described and identical with those shown in FIG. 3A is shown. Thus, FIG. 8 shows an array of four Josephson devices 20, pairs of which are connected in series via word lines 21. Bit lines 22 are disposed in orthogonal relationship with word lines 21 and are similar to control lines 5 shown in FIG. 1. The various elements are disposed on a ground plane 23 of niobium or other superconductive metal and are insulated therefrom by a layer of silicon oxide or other suitable dielectric. Current sources indicated in FIG. 8 by lines labelled I g and I c , which are connected to word lines 21 and bit lines 22, respectively, provide coincident gate and control currents, respectively, which are utilized to store information in and read information from the array shown. Since each of the devices 20 has vortex modes and switching characteristics similar to thosoe shown in FIG. 7, devices 20 can be both written and read by applying the proper coincident currents for writing a binary one or a binary zero and for reading out the stored information. While only four elements have been shown in a portion of an array, it should be appreciated that the present single flux quantum storage devices disclosed herein are particularly applicable to high density arrays which utilize a large number of devices 20.
While the teaching of the present application has been limited up until this point to single Josephson junction devices, it should be appreciated that interferometer devices well known to those skilled in the Josephson tunneling art and consisting of devices similar to that shown in FIG. 1 except that no tunneling occurs in centrally disposed region 9 may also be utilized in the practice of the present invention to the extent that increasing the junction resistance of both Josephson junctions of the interferometer can also extend the switching threshold characteristics of that device in a manner similar to that described in connection with FIG. 6 hereinabove. Thus, an interferometer may be utilized in a regime wherein a single flux quantum is stored and wherein unambiguous coincident current readout is possible in the same way as described hereinabove in connection with FIG. 7. Thus, the Josephson current density profile of an interferometer is similar to that shown for the devices of FIG. 1 and FIGS. 2A-4A except that the magnitude in the centrally disposed region between the pair of Josephson junctions is zero. The profile at its boundaries may be reduced to increase the junction resistance to provide reduced damping and may be accomplished by increasing the thickness of the dielectric in the same manner described in connection with FIG. 1 hereinabove. Of course, in any event, the dielectric thickness should not be so great as to prevent Josephson tunneling across the dielectric. Also, the junction resistance, R j should adhere to the criterion that it be ##EQU6## it being understood that L and C may be varied as discussed hereinabove to adjust the junction resistance. Finally, the interferometer device may be read and written in a manner similar to that described hereinabove in connection with FIG. 7.
While the invention has been particularly shown with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention. | 4y
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a linear actuator, and particularly a linear actuator to convert a rotational movement into a linear movement.
[0003] 2. Description of the Related Art
[0004] A linear actuator is conventionally provided which, for example, converts a rotational movement of a motor into a linear movement of an output shaft.
[0005] For example, in a linear actuator disclosed in Japanese Patent Application Laid-Open No. 2002-122203, the outer periphery of an output shaft is provided with a screw thread while the inner periphery of a nut as a mating member fixedly attached to a rotor of a motor is provided with a screw thread, wherein both of the screw threads engage with each other whereby the rotational movement of the rotor is converted into the linear movement of the output shaft in the axial direction.
[0006] Also, in a linear actuator disclosed in Japanese Patent Application Laid-Open No. 2002-372117, a ball screw system is provided between a rotor and an output shaft, whereby the rotational movement of the rotor is converted into the linear movement in the axial direction.
[0007] In the linear actuator disclosed in Japanese Patent Application Laid-Open No. 2002-122203, the rotational movement of the rotor is transmitted to the output shaft by means of a screw system which has a high friction resistance, and therefore the transmission efficiency is low thus preventing the torque of the motor from being transmitted sufficiently.
[0008] On the other hand, in the linear actuator which is disclosed in Japanese Patent Application Laid-Open No. No. 2002-372117, and which uses a ball screw system, the output shaft is provided with a ball screw, and also a place corresponding to a nut is provided with a ball groove, wherein balls must be circulated without running off from the screw portion, thus resulting in a complicated structure.
SUMMARY OF THE INVENTION
[0009] The present invention has been made in light of the problems described above, and it is an object of the present invention to provide a linear actuator which has a simple structure, and at the same time in which a large thrust force is raised even with a small torque.
[0010] In order to achieve the object described above, according to an aspect of the present invention, there is provided a linear actuator which includes a motor and a screw as an output shaft and in which the rotational movement of the motor is converted into the linear movement of the screw, wherein at least one retainer to hold a plurality of balls is disposed at the inner periphery of a hollow rotor of the motor, a ball screw is formed at the outer periphery of the screw, the balls are engaged with the ball screw such that the screw is set coaxial to the rotor, and wherein the screw provided with the ball screw is moved linearly by means of the rotation of the balls disposed circumferentially at the inner periphery of the rotor.
[0011] In the aspect of the present invention, the linear actuator may include a plurality of retainers disposed to be located apart from each other in the axial direction of the screw.
[0012] In the aspect of the present invention, the linear actuator may include one retainer, and the plurality of balls held by the one retainer may be arranged in a plurality of rows in the axial direction of the screw.
[0013] In the aspect of the present invention, the liner actuator may include a rotation preventing member functioning to prevent the screw from rotating, which functions also to define forward and rearward moving ends of the linear movement of the screw.
[0014] In the aspect of the present invention, the rotation preventing member may be a block which is disposed around the screw and which has an axial cross section having a polygonal shape.
[0015] In the aspect of the present invention, the rotation preventing member may be a pin which is disposed on the screw and which is oriented substantially perpendicular to the axial direction of the screw.
[0016] In the aspect of the present invention, the retainer may have a ring shape.
[0017] And, in the aspect of the present invention, the retainer may have a ribbon shape.
[0018] According to the present invention, a linear actuator can be provided which has a simple structure and in which a large thrust force is raised even with a small torque.
[0019] Specifically, the linear actuator according to the present invention is structured such that a retainer to hold balls is attached to the inner periphery of a rotor without forming a ball groove at the inner periphery of the rotor, whereby a large thrust force is raised even with a small torque.
[0020] Also, the linear actuator according to the present invention includes a force transmission mechanism which incorporates a combination of a screw and balls wherein the friction resistance can be reduced by means of the balls rolling, in comparison to a force transmission mechanism which is conventionally constituted by a screw and nut engagement thus involving a high friction resistance, whereby the torque efficiency can be improved.
[0021] Also, the linear actuator according to the present invention, while maintaining a high precision, can be assembled with a reduced number of component members and with reduced man hours.
[0022] Further, the retainer of the linear actuator according to the present invention can be formed in various configurations thus resulting in a high productivity.
[0023] Still further, the balls can be made of a wide variety of materials, such as metal, ceramic, resin and the like thus resulting in a high productivity.
[0024] And moreover, the linear actuator according to the present invention is structured such that the rotation preventing member functioning to prevent the output shaft from rotating functions also as a stopper member to define the forward and backward moving ends of the output shaft, which contributes to making the assembly easier, and therefore which results in reduced assembly man hours and in a higher productivity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a partial axial cross-sectional view of a linear actuator according to a first embodiment of the present invention, taken at a relevant portion of an output shaft (screw);
[0026] FIG. 2 is a radial cross-sectional view of the linear actuator of FIG. 1 , taken along line II-II;
[0027] FIG. 3 is a perspective view of one of retainers of the linear actuator of FIG. 1 holding balls in place:
[0028] FIGS. 4A and 4B are explanatory views of a portion of the linear actuator of FIG. 1 located in a vicinity of the retainers, wherein FIG. 4A shows a side view of the screw and the retainers, and FIG. 4B shows an axial cross section of the screw and the retainers taken along an axis center of the screw;
[0029] FIG. 5 is a partial axial cross-sectional view of a linear actuator according to a second embodiment of the present invention, taken at a relevant portion of an output shaft (screw);
[0030] FIG. 6 is a radial cross-sectional view of the linear actuator of FIG. 5 , taken along line VI-VI;
[0031] FIG. 7 is a partial axial cross-sectional view of a linear actuator according to a third embodiment of the present invention, taken at a relevant portion of an output shaft (screw);
[0032] FIG. 8 is a radial cross-sectional view of the linear actuator of FIG. 7 , taken along line VIII-VIII;
[0033] FIG. 9 is a perspective view of one of ribbon retainers of the linear actuator of FIG. 7 holding balls in place; and
[0034] FIGS. 10A and 10B are explanatory views of a portion of the linear actuator of FIG. 7 located in a vicinity of the ribbon retainers, wherein FIG. 10 shows a side view of the screw and the ribbon retainers, and FIG. 10B shows an axial cross section of the screw and the ribbon retainers taken along an axis center of the screw.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Exemplary embodiments of the present invention will hereinafter be described with reference to the accompanying drawings.
[0000] A first embodiment of the present invention will be described with reference to FIGS. 1 to 4B .
[0036] FIG. 1 shows a partial axial cross section of a linear actuator 100 according to the first embodiment of the present invention, taken at a relevant portion of an output shaft.
[0037] Referring to FIG. 1 , the linear actuator 100 according to the first embodiment includes a pair of stator units 6 which in combination form a stator assembly, has a hollow cylindrical shape and each of which includes: a coil bobbin 3 ; a coil 5 which is wound around the coil bobbin 3 ; terminal elements 4 through which electric power is supplied to the coil 5 ; and cylindrical stator yokes which are made of a soft magnetic steel sheet and which are formed by sheet-metal processing, and which each have pole teeth arranged at the inner periphery thereof.
[0038] The stator assembly composed of the pair of stator units 6 is fixedly sandwiched between a front housing 1 and a rear housing 11 .
[0039] The linear actuator 100 further includes a rotor which is arranged in the hollow of the stator assembly and which includes: a cylindrical rotor sleeve 9 connected to the front and rear housings 1 and 11 via a pair of bearings 8 , respectively, so as to be rotatable with respect to the stator units 6 of the stator assembly; and cylindrical ring magnets (field magnets) 7 fixedly attached at the outer periphery of the rotor sleeve 9 by, for example, insert fitting.
[0040] In the hollow of the rotor sleeve 9 , a screw 10 as an output shaft is provided coaxially to the rotor sleeve 9 . A ball screw 10 a is formed at the outer periphery of the screw 10 . Retainers 12 , which have a cylindrical ring shape and which are adapted to hold a plurality of balls 13 having a spherical shape, are fixedly attached to the inner periphery of the rotor sleeve 9 by, for example, insert fitting.
[0041] In the second embodiment, two of the retainers 12 are provided respectively at two places of the screw 10 located apart from each other in the axial direction. The number of the retainers 12 , however, is not limited to two and may be three or more. The balls 13 held by the retainers 12 engage with the ball screw 10 a of the screw 10 .
[0042] A pin 2 is inserted in the screw 10 so as to be oriented substantially perpendicular to the axial direction of the screw 10 .
[0043] FIG. 2 shows a radial cross section of the linear actuator 100 of FIG. 1 , taken along line II-II.
[0044] As shown in FIG. 2 , the pin 2 inserted in the screw 10 radially protrudes from the outer periphery of the screw 10 , and on the other hand the front housing 1 has an inner diameter larger than the outer diameter of the screw 10 and at the same time has an inner radius smaller than the dimension which is defined between the axis center of the screw 10 and the top end of the pin 2 radially protruding from the outer periphery of the screw 10 .
[0045] Further, a slit la is arranged at a place of the inner periphery of the front housing 1 located corresponding to the pin 2 . The slit 1 a has a radial cross-sectional geometry substantially analogous to the longitudinal shape of the pin 2 with a slightly larger dimension and has an elongated axial dimension. With the arrangement described above, the pin 2 is prevented from coming off from the slit 1 a and therefore the screw 10 is not allowed to rotate thus moving only forward and backward in the axial direction.
[0046] The slit la is provided with front and rear stopper members which are located at the front and rear ends of the slit 1 a and which are constituted respectively by portions of the front housing 1 and the rotor sleeve 9 against which the pin 2 , when moving forward and backward, hits, whereby the forward and backward moving ends of the screw 10 are defined. That is to say, the pin 2 as a rotation preventing member which prevents the screw 10 from rotating functions also as a stopper member to define the forward and backward moving ends of the linear movement of the screw 10 .
[0047] In this connection, a spring, a washer or the like may be provided at the hitting places to thereby prevent the output shaft from getting stuck at the forward and backward moving ends.
[0048] Description will now be made of the retainer 12 shown in FIG. 1 .
[0049] FIG. 3 perspectively shows the retainer 12 shown in FIG. 1 holding the balls 13 in place.
[0050] FIGS. 4A and 4B illustrate a portion of the linear actuator 100 of FIG. 1 located in the vicinity of the retainers 12 , wherein FIG. 4A shows the side view of the screw 10 and the retainers 12 , and FIG. 4B shows the axial cross section of the screw 10 and the retainers 12 taken along the axis center of the screw 10 .
[0051] Referring to FIG. 3 , a plurality of through-holes 12 a are provided at each of the retainers 12 in such a manner as to be arranged equidistantly from one another in the circumferential direction and located so as to correspond to the ball screw 10 a. Thus, the through-holes 12 a are arranged in a spiral manner on the circumference of the retainer 12 .
[0052] When the balls 13 are put in the through-holes 12 a from the outer periphery of the retainer 12 , the inner tip of the ball 13 protrudes inwardly from the inner periphery of the retainer 12 , and a portion of the ball 13 protruding inwardly is adapted to engage with the ball screw of 10 a of the screw 10 .
[0053] The retainer 12 holds the balls 13 in place, wherein after the retainer 12 is attached to the rotor sleeve 9 , it does not happen that the balls 13 come off. With the structure that the retainer 12 is fixedly attached to the rotor sleeve 9 , the rotation of the rotor sleeve 9 is transmitted to the screw 10 via a point contact of the ball 13 .
[0054] In the first embodiment, the retainer 12 is provided with seven of the through-holes 12 a, which corresponds to the number of the balls 13 . The present invention, however, is not limited to this arrangement, wherein it is desirable that the balls 13 support the outer periphery of the ball screw 10 a of the screw 10 without backlash.
[0055] In this connection, it is not possible to unlimitedly increase the number of the balls 13 in view of the provision of the retainer 12 , so it is preferable to use an odd number of the balls 13 in order to achieve a high precision and a stable load with the least number of the balls 13 .
[0056] If an even number of the balls 13 are used, when a weight is applied laterally (perpendicularly to the shaft), a symmetric position appears, and it can happen that a resultant load is focused on only one of the balls 13 .
[0057] On the other hand, if an odd number of the balls 13 are used, the load is borne by two or more of the balls 13 and thus can be dispersed. Since it is not possible for three of the balls 13 to duly bear the load, and since the load may be focused on one of the balls 13 if four of the balls 13 are used, it is preferable to use at least five of the balls 13 or a larger odd number thereof.
[0058] According to the first embodiment, since the retainer 12 can be fixedly attached in a unified manner, by means of adhesion, insert fitting or a like method, inside the hollow rotor which includes a magnet 7 as well as the rotor sleeve 9 made of metal (stainless steel, aluminum, or the like), the only thing to be done is to set the outer periphery of the magnet 7 coaxial to the inner periphery of the rotor sleeve 9 . Consequently, the linear actuator 100 can be assembly with an increased precision and with reduced man hours.
[0059] It is preferable that the retainer 12 to hold the balls 13 , though not limited in terms of material, be made of metal or abrasion-resistant resin, such as polyacetal (POM) or polyphenylene sulphide (PPS), and also be structured to prevent the balls 13 from falling inside. With such a structure, the assembly can be done easily.
[0060] A second embodiment of the present invention will be described with reference to FIGS. 5 and 6 .
[0061] FIG. 5 shows a partial axial cross section of a linear actuator 1100 according to the second embodiment of the present invention, taken at a relevant portion of an output shaft.
[0062] Referring to FIG. 5 , the linear actuator 1100 according to the second embodiment is substantially the same as the linear actuator 100 according to the first embodiment shown in FIG. 1 except in that one retainer 112 is provided in place of the two retainers 12 and in that a block 14 is provided in place of the pin 2 . So, identical parts and similar have the same reference numbers as in FIG. 1 , and a detailed description thereof will be omitted.
[0063] In the hollow of a rotor sleeve 9 , a screw 10 as an output shaft is arranged coaxial to the rotor sleeve 9 . A ball screw 10 a is formed at the outer periphery of the screw 10 . The aforementioned retainer 112 , which has a circular cylindrical shape and which is adapted to hold a plurality of balls 113 having a spherical shape, is fixedly attached to the inner periphery of the rotor sleeve 9 by, for example, insert fitting. The balls 113 held by the retainer 112 engage with a ball screw 10 a of the screw 10 .
[0064] While each retainer 12 according to the first embodiment shown in FIG. 3 is structured to hold the balls 13 in such a manner that the balls 13 are arranged in one row running around the outer periphery of the screw 10 , the retainer 112 according to the second embodiment is structured to hold the balls 113 in such a manner that the balls 113 are arranged in a plurality of rows running around the outer periphery of the screw 10 . In the embodiment example shown in FIG. 5 , the retainer 112 holds the balls 113 provided with seven of such rows.
[0065] Also, in the second embodiment, the aforementioned block 14 is provided in place of the pin 2 as described above. The block 14 has a polygonal (quadrangular in the second embodiment) cross section taken along a direction substantially perpendicular to the axial direction, and is fixedly attached around the screw 10 .
[0066] FIG. 6 shows a radial cross section of the linear actuator 1100 of FIG. 5 , taken along line VI-VI.
[0067] Referring to FIG. 6 , the block 14 attached around the screw 10 protrudes radially outwardly from the outer periphery of the screw 10 . A front housing 101 , inside which the screw 10 is housed, has a hollow 101 a which has a polygonal radial cross-sectional geometry analogous to and slightly larger than the radial cross section of the block 14 and the wall surface of which is located radially outwardly of the outer periphery of the screw 10 .
[0068] With the arrangement described above, the block 14 , while prohibited from coming off from the polygonal hollow 101 a, is prevented from moving in the circumferential direction, and therefore the screw 10 having the block 14 fixedly attached therearound is not allowed to rotate and thus allowed only to move forward and backward in the axial direction.
[0069] The polygonal hollow 101 a is provided with front and rear stopper members which are located at the front and rear ends of the polygonal hollow 101 a and which are constituted respectively by portions of the front housing 101 and the rotor sleeve 9 against which the block 14 , when moving forward and backward, hits, whereby the forward and rearward moving ends of the screw 10 are defined. That is to say, the block 14 as a rotation preventing member which prevents the screw 10 from rotating functions also as stopper members to define the forward and rearward moving ends of the linear movement of the screw 10 .
[0070] The block 14 may be composed of, for example, two pieces and put together so as to fixedly enclose and grip the small diameter portion of the screw 10 , whereby the assembly can be performed easily while the screw 10 is prevented from rotating and also from axially coming off (that is to say, the forward and rearward moving ends of the linear movement are defined).
[0071] In this connection, a spring, a washer or the like may be provided at the hitting places to thereby prevent the output shaft from getting stuck at the forward and rearward moving ends.
[0072] A third embodiment of the present invention will be described with reference to FIGS. 7 to 10B .
[0073] FIG. 7 shows a partial axial cross section of a linear actuator 2100 according to the third embodiment of the present invention, taken at a relevant portion of an output shaft.
[0074] Referring to FIG. 7 , the linear actuator 2100 according to the third embodiment is substantially the same as the linear actuator 100 according to the first embodiment shown in FIG. 1 except in that two ribbon retainer 212 are provided in place of the two retainers 12 . So, identical and similar parts have the same reference numbers as in FIG. 1 , and a detailed description thereof will be omitted.
[0075] In the hollow of a rotor sleeve 9 , a screw 10 as an output shaft is provided coaxially to the rotor sleeve 9 . A ball screw 10 a is formed at the outer periphery of the screw 10 . Ribbon retainers 212 adapted to hold a plurality of balls 213 having a spherical shape are fixedly attached to the inner periphery of the rotor sleeve 9 .
[0076] In the third embodiment, two of the ribbon retainers 212 are provided respectively at two places of the screw 10 located axially apart from each other. The number of the ribbon retainers 212 is not limited to two and may be three or more. The balls 213 held by the ribbon retainers 12 engage with the ball screw 10 a of the screw 10 .
[0077] A pin 2 is inserted in the screw 10 so as to be oriented substantially perpendicular to the axial direction of the screw 10 .
[0078] FIG. 8 shows a radial cross section of the linear actuator 2100 of FIG. 7 , taken along line VIII-VIII.
[0079] As shown in FIG. 8 , the pin 2 inserted in the screw 10 radially protrudes from the outer periphery of the screw 10 . On the other hand, the inner periphery of a front housing 1 has a larger diameter than the outer periphery of the screw 10 and at the same time has a radius smaller than the dimension which is defined between the axis center of the screw 10 and the top end of the pin 2 radially protruding from the screw 10 .
[0080] Further, a slit 1 a is arranged at a place of the inner periphery of the front housing 1 located corresponding to the pin 2 . The slit 1 a has a radial geometry substantially same as the side shape of the pin 2 with a slightly larger dimension and has an elongated axial dimension.
[0081] With the arrangement described above, the pin 2 is prevented from running off from the slit 1 a and therefore the screw 10 having the pin 2 inserted therein is not allowed to rotate thus moving only forward and backward in the axial direction.
[0082] The slit la is provided with front and rear stopper members which are located at the front and rear ends of the slit la and which are constituted respectively by portions of the front housing 1 and the rotor sleeve 9 against which the pin 2 , when moving forward and backward, hits, whereby the forward and rearward moving ends of the screw 10 are defined. That is to say, the pin 2 as a rotation preventing member which prevents the screw 10 from rotating functions also as stopper members to define the forward and rearward moving ends of the linear movement of the screw 10 .
[0083] In this connection, a spring, a washer or the like may be provided at the hitting places to thereby prevent the output shaft from getting stuck at the forward and rearward moving ends.
[0084] Description will now be made in detail of the ribbon retainer 212 shown in FIG. 7 .
[0085] FIG. 9 perspectively shows the retainer 212 shown in FIG. 7 holding the balls 213 in place.
[0086] And, FIGS. 10A and 10B illustrate a portion of the linear actuator 2100 of FIG. 7 located in the vicinity of the ribbon retainers 212 , wherein FIG. 10A shows the side view of the screw 10 and the ribbon retainers 212 , and FIG. 10B shows the axial cross section of the screw 10 and the ribbon retainers 212 taken along the axis center of the screw 10 .
[0087] Referring to FIG. 9 , the ribbon retainer 212 is composed of two retainer pieces 214 and 215 , which are formed by, for example, pressing a steel sheet.
[0088] The retainer piece 214 includes: a plurality of ball holding portions 214 a which are arranged in an equidistant manner and which are each have a curve formed according to the shape of the ball 213 so that the balls 213 are set around the screw 10 equiangularly; and a plurality of flat portions 214 b which each connect between two adjacent ball holding portions 214 a.
[0089] In the same way, the retainer piece 215 includes: a plurality of ball holding portions 215 a which are arranged in an equidistant manner so as to oppose the ball holding portions 214 a of the retainer piece 214 and which are each have a curve formed according to the shape of the ball 213 so that the balls 213 are set around the screw 10 equiangularly; and a plurality of flat portions 215 b which each connect between two adjacent ball holding portions 215 a. And when the two retainer pieces 214 and 215 described above are coupled to each other, the balls 213 can be held in place around the screw 10 equidistantly.
[0090] The retainer pieces 214 and 215 are put together with the plurality (seven in the present embodiment) of balls 213 sandwiched between the respective ball holding portions 214 a and 215 a, and are fixed to each other by, for example, swaging.
[0091] The balls 213 held by the ribbon retainer 212 are arranged to be located corresponding to the ball screw 10 a of the screw 10 . That is to say, the ribbon retainer 212 is formed spirally in accordance with the spiral of the ball screw 10 a of the screw 10 .
[0092] In the third embodiment, as shown in FIGS. 10A and 10B , a groove 15 shaped according to the ball 213 is formed at the inner periphery of the rotor sleeve 9 and located corresponding to the balls 213 held by the ribbon retainer 212 . The balls 213 are engaged with the groove 15 , and the ribbon retainer 212 is fixedly attached to the rotor sleeve 9 (the ribbon retainer 212 may be fixed to the rotor sleeve 9 by adhesive or the like), and the retainer 212 is caused to rotate in accordance with the rotation of the rotor sleeve 9 .
[0093] In the third embodiment, the groove 15 is formed at the inner periphery of the rotor sleeve 9 , but the present invention is not limited to this arrangement, and the groove 15 may not be formed at the inner periphery of the rotor sleeve 9 wherein the ribbon retainer 212 to hold the balls 213 may be fixedly attached to the rotor sleeve 9 by adhesion, or the like.
[0094] The ribbon retainer 212 is adapted to hold the balls 213 in place, and the balls 213 are prevented from coming off from the ribbon retainer 212 . While the ribbon retainer 212 stays fixedly with respect to the rotor sleeve 9 , the rotation of the rotor sleeve 9 is transmitted to the screw 10 via the point contact of the ball 213 .
[0095] Seven of the ball holding portions 214 a and 215 a of the ribbon retainer 212 as well as seven of the balls 213 are used in the third embodiment, but the present invention is not limited to this arrangement, wherein it is desirable to use five or a larger odd number of balls 213 .
[0096] According to the third embodiment in which the ribbon retainers 212 are employed, the balls 213 are duly held by the ball holding portions 214 a and 215 a and prevented from falling inside or outside.
[0097] The present invention has been explained with respect to the specific embodiments thereof but is by no means limited thereto. It will be apparent to those skilled in the art that numerous modifications and combinations may be possible without departing from the spirit and scope of the present invention, and also various combinations of the compositions of each embodiment may be included in the present invention. | 4y
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BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for debugging faults occurring in a router or other network device and more particularly to compressing core file and storing the compressed core file into an internal flash memory.
Network servers and other types of network devices often experience unrecoverable faults. One example of an unrecoverable fault occurs when a routine writes an invalid address value into core memory. When a process tries to access the illegal address value, a fault occurs. For example, a process may request a memory address for a status register used for conducting a direct memory access (DMA) operation. If the memory address is invalid, a fatal error occurs when the process attempts to access the memory address, which causes the router to reset.
Viewing core files is vital to resolving fatal fault errors. A core file is essentially a copy of DRAM which contains the program, program pointers, program variables, etc. The core file provides a snap-shot of the router at the time the fault occurred. DRAM is used to meet performance requirements of the system and since the contents of the DRAM are destroyed after a reset operation, the core file must be downloaded to another storage device. Routers can be equipped with some flash memory. However, due to the cost of flash memory, the flash memory is not large enough to hold all DRAM contents. Thus, the core file must be downloaded to an external server connected to the router through a local area network (LAN). The core file can then be analyzed by an engineer from a computer or workstation to identify the source of the fault.
The problem with copying a core file to an external device is that the fault condition causing the router to shutdown may be caused by a process that must be operational in order to download the core file. For example, the fault may be caused by a software error with a network protocol or LAN media drivers. If these network interface processes are not operational, the core file cannot be successfully downloaded to an external network device. Thus, in the past, a special image had to be created in order to investigate the fault. The special image is produced by modifying operating code to print out specific identified information before the fault occurs. Generating special images to locate faults requires a large amount of trial and error which is extremely time consuming. Alternatively, the router is taken out of production so that the current content of the main memory can be analyzed with a ROM monitor.
Accordingly, a need remains for a faster more reliable way to save core file after a fault condition occurs in a network device.
SUMMARY OF THE INVENTION
A network device, such as a router or switch, downloads a core file into a local flash memory. In order to increase storage capacity, the core file is compressed before being dumped into the local flash memory. The flash memory is local and internal to the network device. Because network interface elements do not have to be functional for a successful core download, the core download is faster and more reliable than existing download techniques.
In one embodiment, the network device comprises a router having a CPU for controlling packet processing operations. DRAM is used for a main memory and its contents constitutes the core file. Network interface elements are coupled between the CPU and different external networks. The network interface elements process and route the packets received from the external networks. The core file is downloaded from the main memory to local flash memory independently of these network interface elements.
During the shutdown routine, interrupts are disabled for any processing elements, such as the network interface elements, that are not needed to perform the core download. Thus, the CPU is not interrupted by routines that could generate additional fault conditions. Because these processing elements are disabled, the DRAM contents cannot be modified by other processes that might be operating after the fault condition. Thus, the core file will more accurately represent a snapshot of the system at the time the fault condition occurred.
In one embodiment of the invention, the CPU downloads the core file to the same local flash memory used for storing the router operating routine and the router shutdown routine. Router platforms may contain more than one flash memory device and different flash memory configurations. The network device can also be configured by a user to download all or part of the core file into one or more of the different flash memory devices used in the specific platform.
In order to increase download capacity, each byte of the core file is compressed using a standard compression routine. The compressed core file is written into a temporary buffer in main memory. Once the temporary buffer is full, the contents of the buffer are downloaded into the local flash memory.
The router is coupled to a network server through a LAN. The router is reset after completing the core download. The server uses a file transfer operation to access the router and read the core file from local flash memory. The core file is then analyzed to determine the state of the router when the shutdown event occurred.
The foregoing and other objects, features and advantages of the invention will become more readily apparent from the following detailed description of a preferred embodiment of the invention which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a network device according to one embodiment of the invention.
FIG. 2 is a detailed diagram of processing elements in the network device shown in FIG. 1 .
FIG. 3 is flow diagram showing how the network device operates according to the invention.
DETAILED DESCRIPTION
Referring to FIG. 1, a network device 12 is shown in dashed boxes 40 and 41 and is coupled to a LAN 25 . A network device is defined as any system that processes data or communicates through a network. In one embodiment of the invention, the network device 12 comprises a router that processes and transfers network packets to and from different external devices on different networks or buses. A server 26 is coupled to the router 12 through the LAN 25 . The router 12 includes a CPU 14 coupled through an internal bus 13 and a system arbiter 16 to a main memory 18 . The main memory 18 comprises a Dynamic Random Access Memory (DRAM). Multiple memory devices are coupled to bus 13 and include a flash/Read Only Memory (ROM) 20 used for router bootup, an Electrically Erasable Read Only Memory (EEROM) 21 used for configuring the router 12 , and flash memories 22 and 24 used for storing router routines. A PCMCIA card 42 connects the router 12 to PCMCIA compatible devices (not shown).
Multiple network interface elements are shown in dashed box 40 and are used to connect the router 12 to different networks. In the example shown in FIG. 1, the network interface elements 40 include a packet memory arbiter 46 that arbitrates access to a packet memory 44 between an Ethernet or token ring controller 50 and a serial bus controller 54 . A LAN media interface 52 is coupled between LAN 25 and controller 50 . Serial interfaces 32 and 34 are coupled between serial lines (not shown) and controller 54 .
Three slots 59 are connected to data bus connections 55 , a Direct Memory Access (DMA) bus 57 and a Time Division Multiplex (TDM) bus 39 . Telephone line interface cards and modem cards (not shown) are coupled to the slots 59 . Calls received by the telephone line interface card are coupled to the modems through the TDM bus 39 or sent over the DMA bus 57 to the packet memory arbiter 46 . A console 28 accesses the internal bus 13 through a DUART 27 . Other devices access the processing elements in router 12 through an auxiliary port 30 also coupled to the DUART 27 . The network interface elements 40 , CPU 14 and internal memory devices are referred to generally as processing elements.
The general operation of the processing elements described in FIG. 1 are known to those skilled in the art and are therefore not described in further detail. One router using the architecture shown in FIG. 1 is the Model No. 5200 router manufactured by Cisco Systems, Incorporated, 170 West Tasman Drive, San Jose, Calif.
Referring to FIG. 2, the CPU 14 includes an interrupt handler 60 that receives interrupt requests from the different processing elements in the router 12 . The interrupt handler 60 jumps to different routines that service the interrupt requests made by the different processing elements. Interrupt handlers are well known and are, therefore, not described in further detail. The main memory 18 stores the information that constitutes the core file for the router 12 . Core file 61 includes the values of stack pointers, routine variables, the last operating instruction, values set by the last operating instruction, status register addresses, program counters and any other data stored in the main memory 18 .
The local flash memory 22 stores a system image that includes operating routines 62 , a shutdown routine 64 , a compression routine 66 and a flash core copy routine 67 . The operating routines 62 include bootup routines, routing protocols, device drivers, configuration routines, etc. and any other routines used by the router to process data. The CPU 14 starts the shutdown routine 64 after detecting a shutdown event. The shutdown routine 64 uses the flash core copy routine 67 to download the contents of main memory 18 to local flash memory 22 . The flash core copy routine 67 also calls the compression routine 66 that compresses the contents of main memory 18 before being downloaded to local flash memory 22 . The boot flash memory 24 contains a boot program 65 used by the router 12 to boot the operating routine 62 after a reset. The flash core copy routine 67 can alternatively copy part of the core file 61 into a portion of the boot flash memory 24 (core file #2).
During initial configuration of the router 12 , space is preallocated in main memory 18 for a temporary buffer and memory required for compression routines. If space in main memory 18 is allocated to other processes, the CPU 14 might not be able to successfully allocate space in main memory 18 for the temporary buffer when a shutdown event occurs. By preallocating space in main memory 18 , the flash core copy routine 67 is assured of having sufficient space for compressing and downloading core file 61 .
Because volatile DRAM is used for the main memory 18 , the contents of the main memory 18 are lost any time the router 12 is reset. Shutdown events causing a reset occur for any one of a variety of software or hardware faults. For example, a shutdown event occurs when a process loads an invalid address into main memory 18 . When another process tries to use the invalid address, a bus error occurs causing the interrupt handler 60 to call the shutdown routine 64 .
If the shutdown routine attempts to download the core file 61 to server 26 (FIG. 1) via a FTP command, the network interface routine used to conduct the FTP operation may be the same routine causing the fault. The CPU 14 would then be unable to successfully download the core file 61 to server 26 .
The flash core copy routine 67 according to the present invention solves this problem by downloading the core file 61 to non-volatile local flash memory 22 . Thus, the contents of the core file 61 will not be destroyed when the router 12 is reset. Because the flash core copy routine 67 downloads the core file to local memory, operational status of network interface routines and devices will not affect the core file download process.
The flash core copy routine 67 disables interrupts for all processing elements in the router 12 , other than those processing elements used for downloading the core file 61 into local flash memory 22 . For example, the CPU 14 has multiple levels of interrupt priority. When a shutdown event occurs, the CPU 14 is brought up to a higher interrupt level ignoring interrupts at lower levels. Disabling interrupts keeps the CPU 14 from having to service requests generated by interface elements 40 while downloading the core file 61 into local flash memory 22 .
Because other interrupts are disabled, the shutdown routine is not disrupted by the interface elements 40 or other processes. If not disabled, the data in main memory 18 could continue to be modified by the interface elements 40 after the shutdown event. By disabling all unnecessary processing elements, the core file provides a more accurate snapshot of the system at the time the system crash occurred.
FIG. 3 describes how the flash core copy routine 67 downloads the contents of main memory 18 into local flash memory 22 according to the invention. The CPU 14 in step 70 runs a standard boot routine 65 in ROM/FLASH memory 20 that boots an operating routine. Step 72 runs the operating routine. After an instruction is completed in the operating routine, the CPU 14 checks for interrupts from any one of the processing elements in the router 12 . If an interrupt request is detected, the CPU 14 services the interrupt then continues running the operating routine in step 72 .
If a fatal error occurs in decision step 74 , the CPU 14 first stores the address location of the operating routine on a program stack pointer. The address pointer for the shutdown routine 64 is read by the CPU 14 . In step 76 , the shutdown routine 64 calls the flash core copy routine 67 which disables the interrupts for the network interface elements 40 and any other processing elements that are not needed to download the contents from main memory 18 to local flash memory 22 .
The flash core copy routine 67 reads 1 byte from the DRAM 18 in step 78 . Step 80 uses the compression routine 66 to compress and store the compressed byte from DRAM 18 into the temporary buffer in main memory 18 . If the temporary buffer is full in decision block 82 , the compressed data in the temporary buffer is downloaded into the local flash memory 22 in step 84 . Any standard compression routine, such as compression routines using a standard hash algorithm, can be used to compress the core file. One hash based compression routine is explained in U.S. Pat. No. 4,558,302 to Welch.
After the temporary buffer is downloaded into flash memory in step 84 , or if the temporary buffer is not full in decision step 82 , decision step 86 determines whether there are any more bytes in the main memory DRAM 18 . If all bytes of the main memory 18 have been compressed, any remaining compressed data in the temporary buffer is downloaded into local flash memory in decision step 88 . If there is more data in main memory 18 , decision step 86 reads the next byte in step 78 .
The compressed core file 61 can be loaded into the same local flash memory 22 that stores the operating routine 62 and the shutdown routine 64 . Part or all of the compressed core file can also be stored in boot flash memory 24 . If there is insufficient space in local flash memories 22 and 24 , the flash core copy routine 67 stores as many 4K blocks of compressed core file 61 as possible. The remainder of the core file 61 is then downloaded word by word until there is no more space available in the local flash memories. After the compressed core file 61 is downloaded into local flash memory 22 , and possibly flash memory 24 , the router 12 is reset in step 90 .
Usually after the router 12 is reset, the previous fault condition causing the shutdown no longer exists. The compressed core file 61 in local flash memory 22 can then be transferred over LAN 25 using an internet protocol command initiated from the server 26 or router 12 . However, if the network command fails, the compressed core file 61 in local flash memory 22 can be accessed through the console 28 or other devices coupled to auxiliary port 30 .
Having described and illustrated the principles of the invention in a preferred embodiment thereof, it should be apparent that the invention can be modified in arrangement and detail without departing from such principles. I claim all modifications and variation coming within the spirit and scope of the following claims. | 4y
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BACKGROUND OF THE INVENTION
This invention relates to new fluoropolymer containing composites having improved wear resistance characteristics. More particularly, the invention relates to coatings useful in the manufacture of composites which are both flexible and resistant to wear and abrasion. The invention further relates to a novel method for preparing such composites whereby the wear characteristics of relatively hard polymers are imparted to composites, such as woven textile composites, without substantial loss of flexibility.
Perhaps the most well-known subclass of fluoropolymers are substances called "fluoroplastics" which are generally recognized to have excellent electrical characteristics and physical properties, such as a low coefficient of friction, low surface free energy and a high degree of hydrophobicity. Fluoroplastics, and particularly perfluoroplastics (i.e., those fluoroplastics which do not contain hydrogen), such as polytetrafluoroethylene (PTFE), fluoro (ethylenepropylene) copolymer (FEP) and copolymers of tetrafluoroethylene and perfluoropropyl vinyl ether (PFA), are resistant to a wide range of chemicals, even at elevated temperatures, making them widely useful in a variety of industrial and comestic applications. The broad class of fluoropolymers also includes substances called "fluoroelastomers" which are not only elastomeric, but possess to a lesser degree several of the aforementioned physical and electrical properties of a fluoroplastic. Fluoroelastomers, including perfluoroelastomers, however, have a low flex modulus and conformability which is lacking in the more crystalline fluoroplastics.
Fluoropolymers, such as polytetrafluoroethylene, are also well-known for their low coefficient of friction and relatively low surface-free energy which contributes to release behavior. While they exhibit outstanding chemical and thermal resistance, they are soft waxy materials with fragile surfaces easily damaged mechanically by scratching or wearing when rubbed against other materials. It is for these reasons that cookware and other metal surfaces requiring non-stick and/or low friction frequently employ coatings that are combinations of PTFE and relatively harder polymers. Increasing proportions of the harder polymer component in the coating matrix can lead to improved wear characteristics, but with an attendant loss of elongation (embrittlement). While such coating compositions may be reasonably employed on relatively rigid substrates, such as those normally used on coated bakeware, when coated directly onto flexible substrates, such as woven cloth, they result in composites which are most frequently too brittle to serve as flexible products, and even crack when folded upon themselves.
Accordingly, it is an object of this invention to provide a fluoropolymer containing coating for a flexible substrate which will retain its flexibility, exhibit good internal matrix cohesion and substrate to matrix adhesion, and yet possess the improved wear resistant characteristics of the relatively harder polymer coatings, including blends with PTFE.
It is also an object of this invention to provide a fluoropolymer-containing composite which is flexible and possesses good surface wear characteristics, and with the outstanding frictional and release properties of a fluoropolymer.
It is a further object of this invention to provide a method for preparing fluoropolymer-containing composites which exhibit outstanding wear characteristics and a low coefficient of friction.
SUMMARY OF THE INVENTION
In accordance with the invention, fluoropolymercontaining coatings are applied to substrates, preferably textile substrates, to obtain composites which are flexible and not brittle (i.e. they may be folded upon themselves without breaking), and which exhibit a low coefficient of friction, good wear resistance and excellent release properties. This invention comprises the technique of initially coating a flexible substrate, such as glass fabric or a metal mesh, with a fluoropolymer, such as polytetrafluoroethylene (PTFE), prior to the application of an additional layer containing a polymer capable of imparting wear resistance to the finished composite. This technique has been found to prevent the wear-resistant invention composites from cracking upon flexing. The initially coated substrate is thereafter coated with a blend or dispersion of a harder polymer and a fluoropolymer dispersion, such as PTFE, which adheres well to the intermediate coated substrate. The resulting composites are not brittle and exhibit satisfactory flexibility. Significantly, the composites of the invention are flexible yet possess the wear and abrasion resistance associated with the harder polymer component in addition to the good frictional and release characteristics of the fluoropolymer component.
The novel textile composites according to the invention include a substrate, preferably a flexible, textile substrate, coated on one or both faces with a matrix comprising:
(A) an initial fluoropolymer-containing layer, preferably comprising a fluoroplastic, a fluoroelastomer, or blends or combinations thereof; and
(B) an overcoat layer comprising a blend of (1) a polymeric material capable of imparting wear resistance to the finished composite, hereinafter referred to as "hard polymer", and (2) a fluoroplastic, fluoroelastomer or any blend or combinations thereof wherein the fluoropolymer component comprises about 40-90% by weight, preferably about 60 to 80% by weight, of the hard polymer/fluoropolymer blend.
In those embodiments where the overcoat layer on element B, as described above, is separately formed as a film for subsequent transfer to the substrate, the initial layer, or element A as described above, may be other than fluoropolymer-containing. Examples of such composites are described in the copending application of Effenberger and Ribbans, Ser. No. 599,766, also filed Apr. 13, 1984. In those embodiments, the critical layers may comprise any suitable adhesion promoting polymer or chemical which is compatible with the substrate and capable of effecting a bond between the most proximate polymers of any additional layer, including element B above, and itself.
Any suitable reinforcement material capable of withstanding processing temperatures may be employed as a substrate in accordance with the invention. Examples include, inter alia, glass, fiberglass, ceramics, graphite (carbon), PBI (polybenzimidazole), PTFE, polyaramides, such as KEVLAR and NOMEX, metals including metal wire or mesh, polyolefins such as TYVEK, polyesters such as REEMAY, polyamides, polyimides, thermoplastics such as KYNAR and TEFZEL, polyether sulfones, polyether imide, polyether ketones, novoloid phenolic fibers such as KYNOL, cotton, asbestos and other natural as well as synthetic fibers. The substrate may comprise a yarn, filament, monofilament or other fibrous material either as such or assembled as a textile, or any woven, non-woven, knitted, matted, felted, etc. material.
Depending upon the nature of the substrate and the intended end use of the composite, the reinforcement or substrate may be impregnated, either initially or simultaneously with the initial polymer layer, with a suitable lubricant or saturant, such as methylphenyl silicone oil, graphite, or a highly fluorinated fluid lubricant. The lubricant or saturant performs three functions vis-a-vis the reinforcing substrate:
(1) As a lubricant, it protects the substrate from self-abrasion by maintaining the mobility of the reinforcing elements;
(2) As a saturant, it inhibits extensive penetration of the initial polymer coat into the substrate which could reduce flexibility; and
(3) In a finished product, it remains in the substrate to inhibit wicking of moisture or other degrading chemicals through the substrate. The lubricant or saturant may either be applied separately as an initial pass or in combination with the first application of polymeric component.
Alternatively, again depending upon the nature of the substrate and the envisioned end use, the reinforcement or substrate may be treated with a bonding or coupling agent to enhance adhesion of the reinforcement to the most proximate matrix polymers.
DETAILED DESCRIPTION
The initial layer, described as element A above, is applied to facilitate adhesion of the matrix to the substrate while minimally contributing to the stiffness of the final composite. Layer A may comprise one or more components so long as the resulting intermediate remains flexible and bondable to element B. In some embodiments, openings may remain in the substrate to enhance flexibility after application of the overcoat layer or layers. Fluoroploymers suitable for the initial layer are characterized by relatively low modulus and are preferably fluoroplastics, such as PTFE, or fluoroelastomers, such as VITON or KALREZ (DuPont), AFLAS (Asahi), KEL-F (3M), or any blend thereof.
The initial coating is then covered with a layer or layers of a blend of a hard polymer and a fluoropolymer, such as fluoroplastic, fluoroelastomer, or any blend or combination thereof. Preferably, this portion of the matrix includes a layer or layers of a blend containing the hard polymer and the fluoropolymer in such proportions so as to impart any desired balance of known fluoropolymer properties and hard polymer characteristics, particularly wear resistance, to the composite.
Where the element B layer is to be applied as a separate film laminated to the substrate, the initial layer is any adhesion promoting polymer, such as intially uncured rubbers, silicones, urethanes, soft acrylics or chemicals, such as silane or titanate coupling agents, or any composition compatible with the substrate and capable of effecting a bond between the most proximate components of the element B layer and itself.
It has been found that through the selection of the layer A and the layer B, particularly employing the hard polymer/fluoropolymer blends according to the invention, adequate cohesion within the matrix itself and adhesion of the matrix to the substrate may be achieved by thermal means alone, if so desired, without any physical or chemical treatment of the substrate or individual matrix layers and without the use of adhesion promoters. Through the use of the invention matrix and the particular deployment of the layers thereof vis-a-vis each other and the substrate in accordance with the invention method, the ability to maintain an excellent degree of adhesion is achieved, while maintaining flexibility and the desired properties of the different fluoropolymer and hard polymer components of the matrix.
The overcoat layer, element B, comprises a wear resistant fluoropolymer composition, preferably containing a perfluoropolymer, modified with hard polymeric fillers to improve wear characteristics. Examples of such hard polymers include, polyphenylene sulfide, polyimide, epoxy, polyamide imide, polyether sulfone, polyether ketone, polyether imide, polyesters and any other known hard polymers suitable for improving wear characteristics of a coating.
The coating layers of the invention matrix may be applied by dip coating from an aqueous dispersion. Any conventional method, such as spraying, dipping, and flow coating, from aqueous or solvent dispersion, calendering, laminating and the like, followed by drying and baking, may be employed to form the coating, as is well-known in the art. As previously disclosed, the coating layers may be separately formed as films of one or more layers for subsequent combination with the substrate.
The term "fluoroplastic" as used herein shall encompass both hydrogen-containing fluoroplastics and hydrogen-free perfluoroplastics, unless otherwise indicated. Fluoroplastic means polymers of general paraffinic structure which have some or all of the hydrogen replaced by fluorine, including inter alia polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP) copolymer, perfluoroalkoxy (PFA) resin, homopolymers of polychlorotrifluoroethylene (PCTFE) and its copolvmers with TFE or VF 2 , ethylene-chlorotrifluoroethylene (ECTFE) copolymer and its modifications, ethylene-tetrafluoroethylene (ETFE) copolymer and its modifications, polyvinylidene fluoride (PVDF), and polyvinylfluoride (PVF).
Similarly, the term "fluoroelastomer" as used herein shall encompass both hydrogen-containing fluoroelastomers as well as hydrogen-free perfluoroelastomers, unless otherwise indicared. Fluoroelastomer means any polymer with elastomeric behavior or a high degree of compliance, and containing one or more fluorinated monomers having ethylenic unsaturation, such as vinylidene fluoride, and one or more comonomers containing ethylenic unsaturation. The fluorinated monomer may be a perfluorinated mono-olefin, for example hexafluoropropylene, penta-fluoropropylene, tetrafluoroethylene, and perfluoroalkyl vinyl ethers, e.g. perfluoro (methyl vinyl ether) or (propyl vinyl ether). The fluorinated monomer may be a partially fluorinated mono-olefin which may contain non-fluorine substituents, e.g. chlorine or hydrogen. The mono-olefin is preferably a straight or branched chain compound having a terminal ethylenic double bond. The elastomer preferably consists of units selected from the previously mentioned fluorine-containing monomers and may include other non-fluorinated monomers, such as olefins having a terminal ethylenic double bond, especially ethylene and propylene. The elastomer will normally consist of carbon, hydrogen, oxygen and fluorine atoms.
Any fluoropolymer component may contain a functional group such as carboxylic and sulfonic acid and salts thereof, halogen, as well as a reactive hydrogen on a side chain.
Preferred elastomers are copolymers of vinylidene fluoride and at least one other fluorinated monomer, especially one or more of hexafluoropropylene, pentafluoropropylene, tetrafluoroethylene and chlorotrifluoroethylene. Available fluoroelastomers include copolymers of vinylidene fluoride and hexafluoropropylene, and terpolymers of vinylidene fluoride, hexafluoropropylene and tetrafluoroethylene, sold by DuPont as VITON and by 3M as FLUOREL and by Daiken as DAIEL. Additionally, elastomeric copolymers of vinylidene fluoride and chlorotrifluoroethylene are available from 3M as Kel-F. The use of AFLAS, which is a copolymer of TFE and propylene, as manufactured by Asahi, is also contemplated.
Preferred perfluoroelastomers include elastomeric copolymers of tetrafluoroethylene with perfluoro alkyl comonomers, such as hexafluoropropylene or perfluoro (alkyl vinyl ether) comonomers represented by ##STR1## in which R f is a perfluoroalkyl or perfluoro (cyclo-oxa alkyl) moiety. Particularly preferred are the perfluorovinyl ethers in which R f is selected from the groups --CF 3 , --C 3 F 7 , ##STR2## where n=1-4 and X=H, Na, K or F. Particularly contemplated is KALREZ which is a copolymer including TFE and perfluoromethylvinyl ether (PMVE).
The term "polyimide" as used herein encompasses
═N--R.sub.1 --N═R.sub.2 ═
where R 1 is a diamide and R 2 is a dianhydride.
The term polyamidimide as used herein encompasses ##STR3## wherein R 1 and R 2 have the same meaning as above.
If desired, and as is well-known in the art, fillers or additives such as pigments, plasticizers, stabilizers, softeners, extenders, and the like, can be present in the matrix composition. For example, there can be present substances such as graphite, carbon black, titanium dioxide, alumina, alumina trihydrate, glass fibers, beads or microballoons, carbon fibers, magnesia, silica, asbestos, wollastonite, mica, and the like.
In a preferred embodiment, the formation of the coated matrix layers upon the substrate is essentially accomplished in accordance with the invention by a method which comprises the steps of:
1. If necessary or desired, removing the sizes or finishes from the textile substrate material, for example, in the instance of woven fiberglass, by heat cleaning the substrate or scouring a woven synthetic fabric;
2. Initially coating the substrate with a low modulus polymer layer, particularly, a fluoropolymer, which may be applied to one or both faces of the substrate. The low modulus fluropolymer is preferably a perfluoropolymer, including a perfluoroplastic, such as PTFE or low cyrstallinity copolymers thereof, or a fluoroelastomer, such as KALREZ, VITON, AFLAS, or blends of such fluoropolymers. As hereinbefore discussed, a suitable saturant or lubricating agent, preferably methylphenyl silicone oil may also be applied to the substrate either initially or simultaneously with the initial polymer layer. In instances where sufficient flexibility otherwise exists, a coupling agent may be used to enhance the adhesion of the matrix to the substrate, as desired. As previously set forth, the initial coating is applied so as to minimize the stiffness of the composite and may be a relatively light application depending upon the weight and openness of the substrate. As indicated above, where the substrate is coated on only one face, the other face of the substrate may be adhered to a different coating material;
3. Applying as an overcoat layer or layers, either directly upon the intial layer or upon any desired intermediate layer, a blend of (1) a hard polymer and (2) a fluoroplastic, a fluoroelastomer, or any blend or combination thereof; and
4. Further applying, as desired, any optional topcoat layer or layers which do not substantially diminish the flexible or wear resistance features of the composite, such as a thin top coating of PTFE or a selected fluoroelastomer.
The composites of the present invention may be produced, if so desired, by aqueous dispersion techniques. The process may be carried out under the conditions by which the cohesiveness of the matrix and adhesion to the substrate is thermally achieved. A preferred process for the manufacture of invention composites comprises an initial application of a low modulus fluoropolymer from a latex or dispersion to a suitably prepared substrate at temperatures leading to fusing or consolidation of the applied polymer. Following this initial coat, any optional intermediate layer and the overcoat layer comprising a blend of hard polymer and perfluoropolymer derived from a latex or dispersion, is applied in such a manner as to dry the coating, but not to exceed the upper temperature limits of its most thermally labile resinous component. The resulting, partially consolidated coating layers may then be subjected to more modest heat under pressure to further consolidate or strengthen the applied coating. Calendering is a convenient process to achieve this result. Any desired topcoat may then be applied. Thereafter, the composite is subjected to a temperature consistent with that required for fusion of the matrix component with the highest melting point to complete consolidation with minimal heat exposure.
The following additives may be included in the process for formulating the composition of the outermost coating layer: a surface active agent such as an anionic active agent or a non-ionic active agent; a creaming agent such as sodium or ammonium alginate; a viscosity-controlling agent or a thickener such as methyl cellulose or ethyl cellulose; a wetting agent such as a fluorinated alkyl-carboxylic acid, an organic solvent, or sulfonic acid; or a film former.
The invention and its advantages are illustrated, but are not intended to be limited, by the following examples. The examples illustrate composites employing a variety of substrates and coating matrices contemplated by the invention. The test procedures used for the chemical and physical testing and property determinations for the composites prepared according to the invention and the controls are identified below:
______________________________________PROPERTY TEST PROCEDURE______________________________________Weight (oz/sq yd) FED STD 191-5041Thickness (ins) FED STD 191-5030Tensile Strength (lbs/in) Warp FED STD 191-5102 FillTensile Strength after Warp *fold (lbs/in) (or Flex FillFold)Trapezoidal Tear (lbs) Warp FED STD 191-5136Strength FillCoating Adhesion (lbs/in) Dry ** WetDielectric Strength (volts) ASTM D-902Wear Rate ASTDM D-3702(Rotating Ring Wear Test)______________________________________ *This is a comparative flexfold test whereby a rectangular test specimen (long dimension parallel to warp yarns in the "warp test" and parallel to filling yarns in "fill test") is folded at its center, rolled with a weighted roller, ten times, and tested as per G.S.A. 171 #5102. The test values are compared with tensile values for an unfolded specimen. Fold resistance is reported as percent of strength retained after the fold. (I the examples which follow, the results are expressed in actual tensile strength after folding, and the percent retention is not calculated.) **This test measures the adherance of the coating matrix to a substance b subjecting a specimen (prepared from two pieces of the sample composite joined face to face as in making a production type joint or seam) to an Instron Tester, Model 1130, whereby the pieces forming the specimen are separated for a specified length (3") at a specified rate of strain (2"/min.). The average reading during separation is deemed the adhesion value in lbs./in.
This invention applies to a variety of hard polymers, fluoropolymer and perfluoropolymer combinations coated onto a variety of textile substrates. The following examples describe in detail experiments run and results observed with some of the contemplated composites according to the invention and are not meant to limit the scope of this invention in any way. Although glass fabrics were used for experimentation, it should be understood that the invention applies to any textile substrate capable of being coated via conventional dip coat processing or the method set forth in the copending application of Effenberger and Ribbans, Ser. No. 599,766, filed Apr. 13, 1984.
EXAMPLE I
Style 2113 glass fabric (greige weight 2.38 oz/sq yd) was treated with an aqueous dispersion based on Xylan 8330/I (Whitford Corp., West Chester, PA.). It is a product containing particles up to 10 microns in size of PTFE and polyphenylene sulfide (PPS) dispersed in water and containing a small amount of black pigment. The coating was dried at ca. 200° F. and cured at ca. 700° F.
The resulting coated fabric weighed 2.6 oz/sq yd and even at this low weight it fractured when creased. It also exhibited very poor tear strength.
EXAMPLE II
Style 2113 glass fabric (Greige weight 2.38 oz/sq yd) was given two coats of a 60% solids PTFE dispersion (designated TE-3313 and available from Dupont). It was then coated three times with a 50:50 (by volume) blend of TE-3313 and Xylan 8330/I. A final coat of PTFE derived from TE-3313 was then applied over the Xylan/PTFE coatings. Upon each coating the fabric was dried and fused at temperatures up to ca. 700° F. The resulting coated fabric weighed 5.6 oz/sq yd. It was quite flexible and could be repeatedly creased without breaking. The trapezoidal tear strength was measured at 8.5×1.1 lbs (warp x fill) and the coating adhesion was measured at 9.9 lbs/inch. The composite exhibited good tear strength and the coating was well adhered to the substrate.
EXAMPLE III
Three composites based upon Style 128 glass fabric (6.0 oz/sq yd greige weight) were prepared for wear testing. One was coated only with PTFE dispersion. The other two were first coated with two layers of PTFE dispersion. One of them was subsequently coated with a blend of TE-3313 and Xylan 8330/I comprising a 75.3% PTFE/24.7% PPS (polyphenylene sulfide) mixture, by weight. The other was coated with a 55.3% PTFE/44.7% PPS weight blend of a TE-3313/Xylan 8330 I. All coatings were applied and cured using a coating tower. All three fabric samples were tough and flexible and could be creased repeatedly without breaking. They were subjected to the Rotating Ring Wear Test which generated relative wear values. The values obtained showed that the PTFE/PPS based composites exhibited significantly less wear than the 100% PTFE based composite.
______________________________________Sample Wear Value______________________________________100% PTFE 230075.3% PTFE/24.7% PPS 28055.3% PTFE/44.7% PPS 1500______________________________________
EXAMPLE IV
Two composites based upon Style 128 glass fabric (6.0 oz/sq yd greige weight) were prepared for testing. One was prepared by four applications of a mixture of Xylan 3200 and Teflon TE-3313 with fusion of the resins at 700° F. after the final application. Xylan 3200 is a water compatible formulation of a polyester polymer. The blend contained 60.9% PTFE and 39.1% polyester, by weight. The other composite sample was prepared by two applications of TE-3313 followed by four applications of the Xylan/TE-3313 blend. Both composite samples were dried and cured at ca. 700° F. The composite sample prepared with two initial applications of PTFE was tough and flexible, while the composite prepared using only the 60.9% PTFE/39.1% polyester blend, by weight, and lacking the initial PTFE coatings was brittle and broke upon repeated creasing. The tensile strength of the PTFE precoated composite was initially 350 lbs/in. A 40% drop in tensile strength occurred after folding in accordance with the Flex Fold test. The tensile strength of the composite sample lacking the initial PTFE application was initially 560 lbs/in. After folding in accordance with the Flex Fold test, it experienced a 73% drop in tensile strength.
Both composites were tested in an MIT folding endurance tester. The fabric without the initial PTFE application tested to 4100×7700 folds to failure (warp x fill), while the composite with the PTFE pre-coats tested to 76000×61000 folds to failure (warp x fill).
EXAMPLE V
A flexible composite based upon Style 128 fabric was prepared by an initial apblication of two coats of PTFE dispersion followed by five applications of a blend of Xylan 3400 and TE-3313 to one side only. This blend contained 50% by weight PTFE and 50% by weight of a polyamide-imide based upon solids. The initial application of PTFE was conducted at temperatures up to 590° F. The subsequent coats containing the PTFE/polyamide-imide blend were each fused at 700° F.
The resulting flexible composite was more abrasion resistant than a similar composite containing only PTFE. It was subjected to 10,000 cycles on a Model 503 Tabor Abrader, using a 250 gm wt. and CF-10 abrasion wheels. Samples were weighed before and after abrasion. Three determinations of weight gain for the wear resistant composite indicated an average gain of 0.7 milligrams. Samples of an otherwise similar composite based upon PTFE alone were also tested. They lost an average of 6.9 milligrams. These data show substantial improvement in wear resistance for a flexible PTFE/polyamide-imide composite.
EXAMPLE VI
Style 2113 fiberglass fabric was treated with an aqueous emulsion of methyl phenyl silicone oil derived from ET-4327 (Dow Corning) by dilution of 1.5 grams of ET-4327 with 20 grams of water. The fabric so treated was then flexibilized by coating it with PTFE derived from an aqueous dispersion of TE-3313 (Dupont) with a specific gravity of 1.35. This flexible fabric was then overcoated with a blend of PTFE and PPS derived from TE-3313 and Xylan 8330/I (Whitford) respectively, applied in two identical steps.
The final product had a thickness of 4.4 mils and a weight of 4.25 oz/yd 2 . It was characterized by good tear strength (10.1 lbs. warp, 3.6 lbs. fill) and a wear resistance about 5 times better than a dip-coated PTFE control.
EXAMPLE VII
A composite was prepared from Style 2116 fabric by heat-cleaning and coating with an aqueous mixture of PTFE dispersion and phenylmethylsilicone oil in aqueous emulsion such that the oil represents 8% by weight of the combined weight of PTFE solids and the oil at an overall specific gravity of 1.32. This intermediate was then coated with a highly fluorinated elastoplastic blend of PTFE and VF 2 /HFP/TFE terpolymer, followed by six coats of a blend containing 100 pbw TE-3313, 100 pbw Xylan-3400 (containing an aromatic polyamide-imide), 100 pbw H 2 O and 3 pbw L-77 silicone surfactant obtained from Union Carbide. The composite was top-coated with PTFE derived from TEFLON-30 B. The properties of Example VII are listed below:
______________________________________PROPERTY UNITS VALUES______________________________________Weight oz./yd..sup.2 7.67Thickness mil. 5.5Dielectric Strength volts1/4 in. electrode 22002 in. electrode 1500Trapezoidal Tear Strength lbs.Warp 10Fill 14Tensile Strength lbs./in.Warp 200Fill 180Coating Adhesion lbs./in. 3.0______________________________________
Flexible belts prepared from this composite and used on a high speed packaging machine requiring durable release characteristics outlasted conventional belts based upon composites containing PTFE alone by a factor of at least three.
While representative applications and embodiments of the invention have been described, those skilled in the art will recognize that many variations and modifications of such embodiments may be made without departing from the spirit of the invention, and it is intended to claim all such variations and modifications as fall within the true scope of the invention. | 4y
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[0001] This application claims the benefit of priority from provisional application No. 60/834,518 filed on Jul. 31, 2006.
BACKGROUND
[0002] This invention called “Tethered Wind Turbine” relates to wind powered devices that generate energy from the wind, specifically to windmills that are deployed at or above ground or sea level. However, in another embodiment, this invention could also be used to generate energy from undersea water currents, being more appropriately called a tethered underwater current turbine energy generator.
[0003] Windmills in recent years have become more effective and competitive with other energy sources, but most still remain very expensive to install and maintain. As a result, their overall cost per installed kilowatt hour is still high enough that they are only marginally deployed and they contribute only a small amount to the electrical grid. The primary method modern windmills use today is a horizontally-mounted, large diameter, three-bladed propeller that rotates at low revolutions-per-minute over a very large swept area. The higher the rotational axis of the propeller can be mounted, the better. The natural speed of the wind increases proportionally with an increase in the height above the ground. Conventional windmills have very tall and very strong tower structures. Typically they have a tubular steel tower that is mounted to a deep below ground cement base. The system has to be very carefully engineered and sited appropriately for the surrounding terrain. The towers must maintain a central stairway or other means to allow construction and operator access to the upper mechanicals. The tower must accommodate the heavy gearbox, electrical turbine, and propeller assembly, as well as be strong enough to withstand gale force winds, and potentially earthquakes. To make the system even more complicated, the upper nacelle and gearbox/turbine housing must be able to pivot on a vertical axis, so as to align the propeller correctly with the wind direction at any time during the day or night. On many windmill systems the individual blades of the windmill are able to rotate about their individual longitudinal axis, for pitch control. They can optimize the pitch of the blades depending on the nominal wind speed conditions that are present at any one time at the site. They can also change the pitch of the blade to “feather” the propeller if the nominal wind speeds are too large. Occasionally the windmill is locked to prevent rotation, and the blades feathered to prevent major damage to the machine in a storm. All of this pitch control technology adds significantly to the cost of windmills. Another major problem with conventional windmills is damage caused by lightning during thunderstorms. The blades can be upwards of 300 feet in the air and are a good source for lightning to find a conductive path to the ground. Some of the more recently designed windmills use a system of replaceable sacrificial lightning conduction attractors that are built into each windmill propeller blade. They help channel the lightning away from the vulnerable composite structure that comprises the blade itself. The fact remains that one of the major causes of windmill downtime and maintenance costs are caused by lightning damage. The size of many windmills is also a major problem for inspection, diagnostics, and repair. Often workmen have to use ropes and climbing techniques to perform maintenance on the massive machines. It is very expensive and dangerous. In recent years workmen have fallen to their death trying to repair the blades. In conclusion, insofar as I am aware, no current windmill provides competitively inexpensive energy generation without the major defect of highly priced support tower construction and maintenance costs coupled with high risk diagnosis and repair of the large windmill blades themselves.
SUMMARY
[0004] The invention, an improved windmill, is a special design that combines a lighter-than-air structural design with an aerodynamic shape that concentrates the wind's forces through a relatively-higher-RPM yet smaller-diameter turbine generator, thus eliminating the need for a fixed tower. The lighter-than-air machine is tethered to the ground and can therefore freely align itself optimally with the direction of the prevailing wind automatically and with no loss in efficiency. The tether also provides the conductive path for the wind turbine's electrical energy to travel down to the base station where it can enter the grid or be used locally. In one embodiment, the system employs ultra-low weight onboard weather diagnostic computer technology to be able to smartly know when to remain aloft, and when to robotically be retracted and returned to the base shelter to wait-out a potentially destructive storm. This feature would effectively eliminate the lightning damage problem of current windmills.
[0005] Several advantages of the invention are to provide an improved windmill, to provide a means of reducing the cost of wind generated electrical energy, to provide a wind generator with much reduced installation costs, to provide a wind generator with much reduced problems associated with maintenance, bird and bat kills, and downtime due to lightning damage, and to provide a low cost windmill design that is scaleable and that could be affordable and practical for individual home owners and small community cooperatives, as well as an attractive alternative to fossil fuels for large energy companies to use in their electric grid operations. An additional objective would be to produce an embodiment of the invention that would perform well underwater as a lighter-than-water, tethered, sea-current turbine generator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective left-side view of a tethered wind turbine constructed in accordance with the invention, showing primarily the left half of the funnel-shaped wind turbine.
[0007] FIG. 2 is a perspective right-side view of the tethered wind turbine of FIG. 1 .
[0008] FIG. 3 is a longitudinal cross-sectional view of the wind turbine of FIGS. 1 and 2 , showing the fluid flow, internal turbine parts, and control module.
[0009] FIG. 4 is a perspective front view of the wind turbine of FIGS. 1 and 2 , showing an embodiment that uses a rear mounted vertical wing stabilizer.
[0010] FIG. 5 is a perspective left-side view of the wind turbine of FIGS. 1 and 2 , showing an embodiment of the invention that uses one combination of rear wing stabilizers and forward mounted lifting wings to improve stability and performance.
[0011] FIG. 6A is a perspective left-side view of the tethered wind turbine of FIGS. 1 and 2 that shows it in operation at a medium height, being tethered to the base structure on the ground.
[0012] FIG. 6B is a perspective left-side cutaway view of the invention of FIGS. 1 and 2 showing the typical base structure with the hanger doors open and the tethered wind turbine retracted to the top of the main pulley.
[0013] FIG. 6C is a perspective left-side cutaway view of the invention showing the typical base structure with the hanger doors closed and the tethered wind turbine fully captured for ground storage.
[0014] FIG. 6D is a perspective left-side detail view of the tether component of the invention of FIGS. 1 and 2 showing its typical construction.
[0015] FIG. 7A , 7 B, 7 C are longitudinal cross-sectional views of the wind turbine of FIGS. 1 and 2 , showing the harness pitch retractor at various adjustments, and the resultant aerodynamic pitch angle of the tethered wind turbine invention.
[0016] FIG. 8A is a perspective left-side view of the tethered wind turbine of FIGS. 1 and 2 that shows how in one embodiment of the invention a simple tubular tail boom ( 110 ) could be used to mount rear wing surfaces such as vertical stabilizer ( 52 ) and horizontal stabilizer ( 56 ).
[0017] FIG. 8B is a longitudinal cross-sectional view of the wind turbine of FIGS. 1 and 2 , showing how the fluted tail section ( 112 ) could be built to allow outlet air ( 114 ) to exit through slots in the tail boom section itself.
[0018] FIG. 9A , 9 B, 9 C, 9 D are longitudinal cross-sectional views of the wind turbine of FIGS. 1 and 2 , showing how potentially many different section shapes of the gas inflated structure could be used without materially diverging from the scope of this invention.
DETAILED DESCRIPTION
[0019] Detailed descriptions of one or more embodiments of the invention follow, examples of which may be graphically illustrated in the drawings. Each example and embodiment are provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features or described as part of one embodiment may be utilized with another embodiment to yield still a further embodiment. It is intended that the present invention include these and other modifications and variations.
[0020] FIG. 1 is a perspective view taken from the left side from the ground standing upwind of the tethered wind turbine constructed in accordance with the invention. The funnel shaped front inlet ( 14 ) is shaped with an annulus ( 12 ) that directs the oncoming apparent wind into the interior. The lighter-than-air device is passively stabile. It has an elongated airfoil shape. Stability is facilitated by, but not limited to, the overall shape of the lighter-than-air device, or in one embodiment, passive stabilizer aerodynamic surfaces such as non-articulating horizontal, vertical, v-shaped or ring-wing stabilizers. A lower portion of the invention has attachment brackets ( 18 ) that are used to connect the harness ( 20 ) and tether ( 22 ) to the main body casing ( 10 ). Large quantities of wind pass through the inlet ( 14 ), the turbine area of the tethered wind turbine, finally exiting the invention through the outlet ( 16 ). The energy harvesting invention is lighter than air and thus remains aloft in various wind conditions.
[0021] FIG. 2 is a perspective view taken from the right side from the ground standing upwind of the tethered wind turbine constructed in accordance with the invention. The wind entering the inlet ( 14 ) passes over the energy converter. Energy extraction is facilitated by an energy converter such as and for example a turbine ( 24 ) or an impeller rotor ( 26 ) or the like. In this embodiment turbine ( 24 ) is shown near the narrowest part of the hourglass-like internal shape.
[0022] FIG. 3 is a longitudinal cross sectional view of the tethered wind turbine drawn in accordance with the invention. Both the interior and exterior surface profiles, as shown in this view, are designed to be as aerodynamically efficient as is feasible. In the preferred embodiment of this invention the ring-wing section profile optimally would have a very low coefficient of drag. A large portion of the physical aerodynamic shape of the tethered wind turbine is filled with a lifting gas ( 40 ), such as helium. This lifting gas is contained within sealed inflated structures ( 42 ) made from polymers such as aluminized polyester film, polyethylene, or other film. The entire tethered wind turbine may also use an exterior lightweight flexible or lightweight rigid exterior skin to act as a shape structure and to protect the tethered wind turbine from the deteriorating effects of ultraviolet solar radiation. One flexible film that would work well for this purpose in this invention is Tedlar (DuPont) film. A rigid material for the exterior could be composite material such as carbon fiber matrix or carbon nanotubes matrix. The tethered wind turbine has an intake flow concentrator nozzle ( 32 ) just to the interior of the leading edge annulus ( 12 ). There is a flow expansion nozzle ( 34 ) at the outlet ( 16 ) of the invention. Between the concentrator and expansion nozzles there is an energy converter such as and for example a turbine ( 24 ) that energizes an electric generator ( 28 ). It is also envisioned, though not shown, that other types of energy converter devices could be used. For example, one concept envisioned in this invention is to directly convert the rotary motion into electricity and use it onboard the tethered wind turbine to separate water into hydrogen and oxygen through electrolysis, delivering the valuable gases to the ground station through a tubular tether (or a multi-tubular tether), without any conductive wires at all. The hydrogen could be stored in containment vessels on the ground and used for any number of useful purposes.
[0023] The structure of the tethered wind turbine is achieved by several elements. The structural ribs ( 46 ) support the overall shape of the tethered wind turbine and spread the loads of the turbine's ( 24 ) and generator's ( 28 ) mass into the craft in a stable manner. In one embodiment, a light weight way to create the structure of the annulus ( 12 ) is shown, using an inflated toroidal structure ( 44 ) that is filled with pressurized lifting gas ( 40 ). There are many ways to achieve the necessary structure, and what is shown is meant to be an example of one embodiment of the invention. The rotor impeller ( 26 ) is fitted with a streamlined impeller nosecone ( 36 ) and impeller tail cone ( 38 ). The electric generator ( 28 ) can be any combination of magnetic rotor or magnetic stator designs, either brush or brushless, and made of a variety of materials. The preferred embodiment would use ultra-light-weight rare earth permanent magnets with brushless DC components and windings that could possibly consist of carbon nanotube hyper-conductive wires in place of copper to save even more weight. There are conductive generator output wires ( 76 ) connecting the generator to the harness ( 20 ). The harness ( 20 ) is secured to the tethered wind turbine at attachment brackets ( 18 ). Said attachment brackets ( 18 ) could be hard mounted to the internal structure or physically attached or bonded to the outer skin of the tethered wind turbine. The harness ( 20 ) can be rigidly attached, or mounted in such as was as to allow controllable adjustments by mechanical servo-actuators. One embodiment of this feature, a harness pitch adjustor ( 50 ), is shown and is a way to control the tethered wind turbine's angle of attack by lengthening or shortening the central member of a three point harness ( 20 ). The control box ( 48 ) is the central brain for the onboard functionality of the tethered wind turbine, controlling such as the harness pitch adjustor ( 50 ), the flight settings, the generator loading, and any aerodynamic control surfaces, etc.
[0024] FIG. 4 is a perspective front view of the tethered wind turbine and shows an embodiment of the invention that includes a vertical stabilizer ( 52 ) mounted at the top and to the rear of the craft. The full front of the impeller rotor ( 26 ) and impeller nose cone ( 36 ) are visible and are described visually as having 5 blades. Any number of impeller rotor ( 26 ) blades would be acceptable and part of the intent of this invention. The outer casing ( 10 ) of the lighter-than-air is shown, as well as the flow concentrator nozzle ( 32 ) and the annulus ( 12 ). Attachment brackets ( 18 ) secure the harness ( 20 ) to the tethered wind turbine. The harness ( 20 ) is also shown secured to the tether ( 22 ).
[0025] FIG. 5 is a perspective left side view of the tethered wind turbine. Showing an embodiment built in accordance with the invention that uses a number of aerodynamic lifting and control surfaces to enhance the overall stability and performance of the wind energy extracting craft. Vertical stabilizer ( 52 ) and horizontal stabilizers ( 56 ) act to further help keep the longitudinal axis of the turbine ( 24 ) aligned with the apparent wind direction. These aerodynamic surfaces can be either passive, or actively controlled with the use of stabilizer control surfaces ( 54 ). A wing ( 58 ) is shown in this embodiment and can add additional lift to the tethered wind turbine to help it remain at altitude even when the wind conditions attempt to blow the craft downwind and downward. Wing control surfaces ( 60 ) are shown and help control roll as needed. These control functions are envisioned to be fully controlled by the onboard control module ( 48 ).
[0026] FIGS. 6A , 6 B, and 6 C show the tethered wind turbine as a system that is managed from a base shelter structure ( 68 ). This base shelter structure ( 68 ) would be pre-built and carried to the site or it could be built on the site. It would also be installed atop housing or buildings or concealed below grade.
[0027] FIG. 6A is a left-side perspective with cutaway view of the tethered wind turbine and base shelter structure ( 68 ) showing the invention in operation. The tethered wind turbine is flying at a reasonable height above the ground, downwind of the base shelter structure ( 68 ), and is constrained by the tether ( 22 ). The craft can be expected to float freely downwind in any direction as a result of changes in true wind direction. The total airspace occupied by the tethered wind turbine in the long term can be described as an inverted cone emanating from the tether main attachment at the robotic control torus ( 72 ). The top diameter and half angle of the inscribed cone is dependent on many variables such as the total buoyancy force of the invention, maximum wind speed, amount of active flight controls used to maintain altitude, and active tether extension/retraction deployed, and turbine generator load levels. To send the tethered wind turbine to a higher or lower altitude while in flight, the tether ( 22 ) is unwound or wound-up on the tether retractor reel ( 74 ) by the tether retractor mechanism ( 64 ). The cutaway view of the base shelter structure ( 68 ) also shows a wish-bone launch arm ( 100 ) that swings up when the tethered wind turbine is about to be launched and also swings down when the craft is retrieved and tucked into the base shelter structure ( 68 ) for safe storage. This wish-bone launch arm ( 100 ) mechanism may be shaped differently, such as having one leg instead of the wish-bone shape, but all versions act as a lever to initially move the tethered wind turbine up out of the base shelter structure ( 68 ) or down within the its walls. The entire base shelter structure ( 68 ) sits on a site pad ( 98 ).
[0028] FIG. 6B is a perspective cutaway view of the tethered wind turbine near the middle phase of the launching process, or the retrieving for storage process. In the latter, the tethered wind turbine has been pulled down out of the sky to a point where the harness ( 20 ) touches and interacts with the robotic control torus ( 72 ). It shows the base shelter structure ( 68 ) with its hinged bay doors ( 92 ) opened wide. The wish-bone launch arm ( 100 ) is in the upright position and the launch arm actuators ( 102 ) are fully extended. Energizing the reel motor ( 66 ) causes the rotation of the tether retraction reel ( 74 ), which is bi-directional in this embodiment of the invention. It rolls the tether retraction reel ( 74 ) in one direction to wind-up (retract) the tether ( 22 ) and rotates the reel in the opposite direction to unwind the tether ( 22 ), allowing the buoyant tethered wind turbine to ascend upward into the airspace above. The control of the reel motor ( 66 ) is accomplished with the logic that is built into the retractor control module ( 62 ). Also shown are the reel-to-power box cables ( 78 ) that deliver electricity from the tether ( 22 ) to the power control/conditioning box ( 70 ) where the electrical characteristics are tailored to meet desired output specifications of a particular application. Power from the tethered wind turbine invention is delivered to the end use through the output plug box ( 96 ).
[0029] FIG. 6C is a perspective left-side cutaway view of the entire tethered wind turbine and base shelter structure ( 68 ) as a system that has been put into the storage mode where the inflated casing ( 10 ) and other components are safe from excessive weather conditions such as lightning, turbulent high winds, and wintry blizzards. In this state, the tether ( 22 ) is fully wound-up by the tether retractor mechanism ( 64 ) onto the tether retractor reel ( 74 ). The wish-bone launch arm ( 100 ) is in the lower position and the launch arm actuators ( 102 ) are fully retracted. The hinged bay doors ( 92 ) are shown in the closed position. Meteorological sensors ( 104 ) on the base shelter structure ( 68 ) monitor the air-space and keep the tethered wind turbine safely contained until conditions are appropriate for launching in the future.
[0030] FIG. 6D is a perspective detail view of the tether ( 22 ) itself. Within the outer casing ( 82 ) of the tether are two critical components. They are the main tensile members ( 84 ) and the electrical wires. Both the positive conductor wires ( 86 ) and negative conductor wires ( 88 ) are sheathed in an insulation jacket that prevents short-circuiting and power drainage. Ideally, the main tensile members ( 84 ) and the positive conductor wires ( 86 ) and negative conductor wires ( 88 ) would be comprised of carbon nanotubes materials. Although these materials are not a requirement, the use of carbon nanotubes materials in these components of the tether ( 22 ) would greatly enhance the overall performance of the tethered wind turbine. That is because the tether ( 22 ) itself is a parasitic weight loss acting against the tethered wind turbine's buoyancy. Carbon nanotube materials would make the tether ( 22 ) itself many times lighter and allow the tethered wind turbine to fly much higher using less lifting gas ( 40 ). Electrical conductance of nanotube wires would be many times higher than copper and would enhance overall efficiency greatly. In lieu of carbon nanotubes materials, many other materials would also work well. Some examples are copper core conductors, Spectra™ fiber tensile members, Kevlar™ fiber tensile members, or polyester fiber tensile members.
[0031] FIGS. 7A , 7 B, and 7 C are longitudinal cross-sectional views that show how pitch attitude of the tethered wind turbine interacts with the apparent wind. In FIG. 7A the aerodynamic shape of the inflated casing ( 10 ) is a ring-wing that is in a neutral angle of attack.
[0032] FIG. 7B shows the tethered wind turbine in a negative angle of attack ( 106 ). This maneuver is accomplished by various means. Shown in this view the harness pitch adjustor ( 50 ) has let out some length of the central line of the harness ( 20 ) causing the buoyant rear end of the inflated casing ( 10 ) to be moved upward relative to the front end. In this state the flying ring wing is going to descend. Another way to accomplish this negative angle of attack ( 106 ) is by using the aerodynamic control surfaces of the horizontal stabilizer ( 56 ) or the wing control surface ( 60 ).
[0033] Conversely, as is shown in FIG. 7C , the harness pitch adjustor ( 50 ) has pulled in the central line of the harness ( 20 ) causing the rear end of the inflated casing ( 10 ) to be moved downward relative to the front end. This positive angle of attack ( 108 ) would cause the flying ring-wing tethered wind turbine to ascend, and allow the energy harvesting turbine system to increase electrical output without as much loss of altitude. The higher loading of the turbine would mean more total drag on the impeller rotor ( 26 ), and a tendency to descend. This could be balanced-off or improved by calling for an even larger positive angle of attack ( 108 ) maneuver, and a tendency to ascend.
[0034] FIG. 8A is a perspective left-side view of the tethered wind turbine showing how in one embodiment of the invention a tubular tail boom ( 110 ) could be used to mount rear stabilizer wing surfaces.
[0035] FIG. 8B is a longitudinal cross-sectional view of the wind turbine of FIGS. 1 and 2 , showing how the fluted tail section ( 112 ) could be built to allow outlet air ( 114 ) to exit through slots in the tail boom section itself.
[0036] FIG. 9A shows a longitudinal cross-section of the wind turbine of FIGS. 1 and 2 that has a elongated profile of the airfoil-shaped inflated casing ( 10 ) of the invention. FIG. 9B is a potential shape that embraces a very short longitudinal airfoil profile of the inflated casing that may be efficacious due to its large annulus ( 12 ) outside diameter relative to its turbine diameter and air outlet ( 16 ) outside diameter. A prominent feature of this embodiment of the invention is the large concentration ratio of the front inlet ( 14 ) flow concentrator nozzle ( 32 ). It appears the concentration ratio is nearly 6 to 1, or higher. FIG. 9C shows almost the opposite inlet ( 14 ) style. That is, it shows a very minor attempt to concentrate the wind at the inlet ( 14 ) flow concentrator nozzle ( 32 ). The concentration ratio is nearly 1 to 1. FIG. 9D is a longitudinal cross-sectional view of yet a different section shape and construction style. In this view the bulk of the lifting gas ( 40 ) within the inflated casing ( 10 ) is located in the annulus ( 12 ) of the front inlet ( 14 ). The remainder of the flow concentrator nozzle ( 32 ) in this embodiment is analogous to a wind-sock, comprising a thin cone-shaped wall, whether of rigid or flexible material. As with a wind-sock, the cone-shape become more pronounced by the wind flowing through it, All of these gas inflated structures and many more could be designed and manufactured without materially or significantly diverging from the scope of this invention.
REFERENCE NUMERALS
[0037]
[0000]
10
inflated casing
12
annulus
14
inlet
16
outlet
18
attachment bracket
20
harness
22
tether
24
turbine
26
impeller rotor
28
electric generator
30
flowing fluid (air = wind,
32
flow concentrator
water = current)
34
flow expansion nozzle
36
impeller rotor nose cone
38
impeller rotor tail cone
40
lifting gas
42
gas containment film
44
inflated toroid
leading edge structure
46
internal structure
48
control module
50
harness pitch adjustor
52
vertical stabilizer
54
stabilizer control surface
56
horizontal stabilizer
58
wing
60
wing control surface
62
retractor control module
64
tether retractor mechanism
66
reel motor
68
base shelter structure
70
power conditioner box
72
robotic controlled torus
74
tether winding reel
76
generator output wires
78
cables-reel to power control
80
power output wires
box
82
outer casing
84
main tensile member
86
positive conductor wire
88
negative conductor wire
90
conductor wire insulation
92
hinged bay door
94
pulley system
96
output plug box
98
site pad
100
wishbone launch arm
102
launch arm actuators
104
meteorological
analysis module
106
negative angle of attack
108
positive angle of attack
110
tubular tail boom
112
fluted tail section
114
outlet air
Operation
FIGS. 1 , 2 , 3 , 4 , 6 , 7
[0038] FIG. 1 and FIG. 2 show the component of the tethered wind turbine invention that extracts energy from wind currents. The inflated casing ( 10 ) is filled with helium or other lifting gas ( 40 ) which makes the tethered wind turbine lighter than air. It also is shaped to scoop-up and aerodynamically force large amounts of air to move through its own interior. The inflated casing ( 10 ) is shaped like an airfoil wing that has been bent all the way around into a ring. At the front, a funnel-shaped inlet ( 14 ) is surrounded with an annulus ( 12 ) at the leading edge. Together they direct oncoming apparent wind into the central part of the ring-wing shape and into a smaller and smaller opening. The wind then passes into the mouth of a rotary engine turbine ( 24 ), and finally exits out the rear outlet ( 16 ) to return to the atmosphere.
No Need for a Gearbox
[0039] The flow concentrator nozzle ( 32 ) gradually directs a large cross-sectional area of slower-moving air to a smaller cross-sectional area, but higher velocity duct full of air. The laws of aerodynamics say that air moving two times faster will carry eight times more energy. It is apparent that an aerodynamically shaped device that can concentrate and accelerate the apparent wind in a controlled manner will be very helpful in extracting energy from the wind. It is the intent of this invention to use the flow concentrator nozzle ( 32 ) to make a large cross-sectional area of slower-moving air to move through a smaller cross-sectional area at a higher velocity through the turbine ( 24 ). This reduces the size of the physical hardware of the turbine ( 24 ) and enables it to operate at a higher speed without the need for an up-ratio gear-box.
[0040] FIG. 3 shows that the turbine ( 24 ) is mounted centrally in the inflated casing ( 10 ). Air currents can flow through it imparting energy to the turbine ( 24 ). The kinetic energy of a flowing fluid ( 30 ), such as flowing wind or running water or the like, is converted into mechanical or electrical energy by causing the blades of the impeller rotor ( 26 ) on the turbine ( 24 ) to rotate as it passes through. Output of electrical energy harvested from the wind will be maximized when the wind throughput of the turbine is maximized. So every effort to streamline the interior surfaces is very important and has been attempted to be shown in this preferred embodiment of the invention.
No Tower Needed
[0041] In most places on earth, the wind speed, and thus potential kinetic energy that could be harvested is distributed in a gradient relative to ground, which could be described as increasing as one moves to a higher altitude. Unlike most windmills currently available, the tethered wind turbine of this invention operates without a tower. It simply does not need a tower. The preferred embodiment of this invention uses a tether ( 22 ) to hold the inflated casing ( 10 ) and its turbine ( 24 ) from sailing downwind with the force of available winds.
No Nacelle Needed
[0042] The tethered wind turbine also has no need for a complicated rotating nacelle as is currently used in the prior art to align properly with the direction of the true wind. The tethered wind turbine has a unique ability to keep itself aligned properly to the wind automatically, even in changing wind conditions. The inflated casing ( 10 ) will naturally drift to the most downwind position in the sky, being restrained only by the tether ( 22 ). Just like the rudder on an airplane, the invention directs itself in response to the changing wind's direction.
Flying the Tethered Wind Turbine
[0043] FIG. 6A is a view looking downwind at the invention while it is operating. The tether ( 22 ) can be let-out, or pulled-in, in a controlled way so as to position the inflated casing ( 10 ) in the most favorable part of the natural wind velocity gradient. That is an altitude where the energy extracted from the wind can be maximized.
[0044] As is shown in FIG. 6A , 6 B, 6 C the tethered wind turbine invention uses a base shelter structure ( 68 ) to store the lighter-than-air device during inclement weather conditions, violent lightning, periods of non-use, or for routine maintenance.
[0045] FIG. 6A shows the tether ( 22 ) after it has been let out and the hinged bay doors ( 92 ) are closed. The retractor control module ( 62 ) remains idle while the production of energy aloft in the turbine ( 24 ) proceeds uninterrupted. The electrical power sent down the tether ( 22 ) travels through the tether retractor mechanism ( 64 ), through the reel-to-power box cables ( 78 ), and into the power conditioner box ( 70 ). At this stage the electricity is adjusted to a form that is compatible with the end user electrical specifications and exits the system through the output plug box ( 96 ).
[0046] FIG. 6B shows the tethered wind turbine in the middle stage of launching or retracting. At this stage the tether ( 22 ) is fully retracted, the wishbone launch arm ( 100 ) is in the upright position and the hinged bay doors ( 92 ) are wide open. If in launching mode, the tether ( 22 ) would be let out, the lighter-than-air inflated casing ( 10 ) would ascend slowly upward. If in the retracting stage, the robotic control torus ( 72 ) would rotate the inflated casing ( 10 ) until the craft aligned properly with the hinged bay doors ( 92 ) and then ready the system for final stage.
[0047] FIG. 6C shows the final stage of the tethered wind turbine when the inflated casing ( 10 ) is in the completely stored mode. The wishbone launch arm ( 100 ) is in the lowered and horizontal position resting underneath the inflated casing ( 10 ). The hinged bay doors ( 92 ) are closed and the entire system is in standby mode.
Controlling the Tethered Wind Turbine
[0048] The preferred embodiment of the invention would have a smart logic circuitry built into it. The control module ( 48 ), shown in FIG. 3 , would make many decisions about when, where and how to fly the tethered wind turbine. The onboard automatic-pilot feature of the control module ( 48 ) would send control voltage signals to various aerodynamic control mechanisms to tune the flight of the tethered wind turbine and thereby achieve a desired ascent trajectory and altitude.
[0049] At launch, there would be software programmed to fly the lighter-than-air tethered wind turbine in a controlled, stable ascent. The tethered wind turbine's ascension could be stable in zero-wind conditions, or, even in rough and gusty wind conditions. This auto-pilot feature to maintain straight and level flight during fluctuating of wind currents broadens the potential application to many geographic locations that otherwise may not have been feasible.
Controlling the Angle of Attack
[0050] Controlling the angle of attack of the inflated casing ( 10 ) is essential for flight control. By controlling the angle of attack, the flying ring-wing-like tethered wind turbine would be able to ascend on command to a predetermined altitude to achieve the best position in a given environment. Once at the favorable altitude the tethered wind turbine would electronically load-up the electrical generator ( 28 ) to increase electrical output.
[0051] As shown in FIG. 7A , 7 B, 7 C one way this invention controls the angle of attack, the flight, and ultimately the altitude, of the inflated casing ( 10 ) is to change the characteristics of its attachment at the top of the tether ( 22 ). The attachment as shown in this embodiment of the invention utilizes a three-point flexible harness ( 20 ). It has a method to adjust it as so as to change the angle of attack and therefore the amount of lift on the inflated casing ( 10 ). It is the intent of this invention to use the tether's ( 22 ) harness pitch adjustor ( 50 ) device to vary the overall amount of lift on the inflated casing ( 10 ) and thereby control the altitude it operates at. The harness pitch adjustor ( 50 ) does this by extending or reeling-in the center rear harness tension member with a servo motor mechanism. By adjusting the harness ( 20 ) attachment in the above described way the overall angle of attack and hence the total lift of the ring-wing-like inflated casing ( 10 ) is controlled. The desired altitude is either dialed into the control module ( 48 ) or determined automatically by a software algorithm that takes into account several variables.
[0052] The benefit using the harness pitch adjustor ( 50 ) as envisioned in this invention to control angle of attack of the inflated casing ( 10 ), a larger amount of electrical output would be achieved with less loss of altitude. In the absence of any angle of attack flight controls such as the harness pitch adjustor ( 50 ), higher loading of the turbine ( 24 ) would mean increased drag on the blades of the impeller rotor ( 26 ), an increased total drag on the inflated casing ( 10 ), and a general tendency for it to descend. This suboptimal condition could be improved by the use of the harness pitch adjustor ( 50 ) of this invention, as described above.
[0053] There is one balance of forces that naturally occurs with the tethered wind turbine invention. If winds escalate while the invention is operating, the overall forces increase on the inflated casing ( 10 ). The natural reaction is for it to be drawn farther downwind and arc-tangentially lower according to the radius struck by the length of tether extended at that time. Other things remaining equal, the craft moves down to a lower altitude and hence a lower energy level in the natural wind velocity gradient. This will reduce forces on the inflated casing ( 10 ) and result in a convergence toward a natural equilibrium.
Controlling the Generator
[0054] The control module ( 48 ) also sends control signals to the tethered wind turbine's electric generator ( 28 ) circuitry. For example, in favorable wind conditions the kinetic energy of the moving air flow develops lift on the turbine ( 24 ) blades, turning the impeller rotor ( 26 ) and electric generator ( 48 ). The only thing resisting the impeller rotor ( 26 ) turning motion is the amount of load, or field resistance, that the electric generator ( 28 ) demands at a given point in time. The load setting is a controllable variable that the control module ( 48 ) can monitor and adjust. The tethered wind turbine utilizes the generator loading configuration to maximize power output but at the same time retain adequate air stability and altitude. The more load levied on the impeller rotor ( 26 ), the more overall wind drag will be developed on the craft. The total induced drag on the lighter-than-air inflated casing ( 10 ) shows up as a tensile force on the tether ( 22 ) along a vector in the downwind direction. The tension in the tether ( 22 ) is resisted by a mass below. The control module ( 48 ) ideally should balance power output versus positional stability and drag management. The control module uses electronic hardware and software as is necessary to accomplish this goal.
Control of Electrical Output
[0055] The control module ( 48 ) also may condition the electricity that is output by the electric generator ( 28 ). In may invert the voltage up to a higher voltage for the purpose of efficiently transferring the generated power down the tether ( 22 ) to the base shelter structure ( 68 ) below. There would be lower line losses experienced if the electricity traveling down the tether ( 22 ) were voltage-adjusted higher. The control module ( 48 ) would handle this function.
[0056] In summary, the control module ( 48 ) of the tethered wind turbine performs the following functions:
controls straight and level flight of the inflated casing ( 10 ) using aerodynamic control surfaces controls straight and level flight of the inflated casing ( 10 ) using harness pitch adjustor ( 50 ) controls load levels applied to electric generator ( 48 ) converts or inverts voltages as necessary to optimize efficient energy transfer down the tether ( 22 )
Operation of Additional Embodiments
FIG. 5
[0061] There are actually two ways this invention proposes to accomplish varying the angle of attack so as to control the flight and altitude of the inflated casing ( 10 ). The first way to would be to use automatic electrical control of the harness pitch adjustor ( 50 ) as described above.
[0062] In an additional embodiment of the invention, angle of attack would be controlled using additional wings, stabilizers and other aerodynamic control surfaces. The net affect would be increased control of total lift of the inflated casing ( 10 ) and an ability to control its altitude.
[0063] FIG. 5 shows one such additional embodiment of the tethered wind turbine invention using aerodynamic control surfaces of many types. These include any and all types of active or passive in-stream surfaces as are typically found on, but not limited to, conventional aircraft such as a horizontal stabilizer ( 56 ), vertical stabilizer ( 52 ), stabilizer control surface ( 54 ), and any type of wing ( 58 ), or wing control surface ( 60 ). It is unlikely that all of these would be necessary.
[0064] It is also the intent in this additional embodiment of the invention, for inflated casing ( 10 ) to use its aerodynamic surfaces to soar to higher heights than would otherwise be possible in an effort to counteract the craft's downward altitude tendency caused by power extraction induced drag of the turbine ( 24 ).
[0065] It should be noted that the inflated casing ( 10 ) of the tethered wind turbine could be secured to ground through a less sophisticated tether system and it will still be a valuable energy extracting machine in the sky. Or it could be outfitted to operate somewhat autonomously with its own internal smart-chip controller and sophisticated controls for its harness pitch adjustor or its aerodynamic wing control surfaces ( 60 ). The latter would probably come closer to maximizing energy production efficiency, but would likely cost more to manufacture. It is a trade-off. The tethered wind turbine invention as described in this document leaves room to cover both.
Adapting to Weather
[0066] It is envisioned that an additional embodiment of the invention would have a micro-meteorological analysis module ( 104 ) onboard that could automatically obtain samples and or use sensors to collect enough data in real time to be able to judge the likelihood of lightning or other hazardous weather conditions. With knowledge of the meteorological facts, including but not limited to, data on humidity, precipitation, temperature, atmospheric pressure, the presence of ozone, or audio-visual signatures, the tethered wind turbine could be programmed to do certain things. It would run the data through a decision formula that could prompt actions such as immediately descending the inflated casing ( 10 ) to a safer altitude by reeling in the tether ( 22 ). Other times in truly inclement weather, it could fully retract the invention to the safety of the base shelter structure ( 68 ). This could all be done automatically and would prevent catastrophic failures as otherwise could be experienced from such hazards as lightning strikes, tornado-like wind currents, or destructive hail. The meteorological analysis module ( 104 ) could optionally be located in the base shelter structure ( 68 ) or other place not onboard the inflated casing ( 10 ).
Operation of Alternative Embodiments FIGS. 8 , 9
[0067] FIG. 8 A shows an alternative design of the tethered wind turbine that utilizes a very simple boom and rear stabilizer arrangement. It represents a direct and simple method of construction.
[0068] FIG. 8B shows another more fanciful arrangement where the exit of air from the turbine ( 24 ) is through a number of slots in the sidewalls of the tail structure.
[0069] FIG. 9A , 9 B, 9 C, and 9 D show how the tethered wind turbine invention could still perform as explained above but with different ring-wing cross-sectional profiles. FIG. 9A is an elongated version of the preferred embodiment of this invention. FIG. 9B is a more exaggerated version with the turbine ( 24 ) located very near to the air outlet ( 16 ) and the flow concentrator nozzle ( 32 ) exhibiting a larger concentration of cross-sectional area ratio. FIG. 9C shows a profile that has the turbine ( 24 ) located near the leading edge annulus ( 12 ) with a very small concentration of cross-sectional area ratio. FIG. 9D is profile with most of the inflated part reserved to the front annulus ( 12 ) itself.
ADVANTAGES OF THE TETHERED WIND TURBINE
[0070] It can be seen that the tethered wind turbine of this invention:
Provides a new way to extract the kinetic energy from the wind. Allows use of a smaller, lighter-weight, higher-speed turbine generator that does not need for an expensive and bulky up-ratio gearbox between the impeller rotor ( 26 ) and the electric generator ( 28 ). Operates without the need for a tower. Has no need for a complicated rotating nacelle to align rotating blades with the wind. Uses lift generated from its overall shape or from horizontal wings so that it can operate higher aloft than would otherwise be possible while extracting energy from the wind. Has a control module that can monitor flight and weather variables and then react to control trajectory, position, stability, altitude, generator loading levels and power output. Has the capacity to retract the tether ( 22 ) and inflated casing ( 10 ) to a lower altitude or ultimately all the way into the base shelter structure ( 68 ) to avoid damage from lightning or severe weather.
[0078] While embodiments of the present invention have been described with reference to the aforementioned applications, these descriptions of the embodiments are to be construed in a limiting sense. It shall be understood that all aspects of embodiments of the present invention are not limited to the specific depictions, configurations or dimensions set forth herein which depend upon a variety of principles and variables. Various modifications in form and detail of the disclosed apparatus, as well as other variations of the embodiments of the present invention, will be apparent to a person skilled in the art upon reference to the present disclosure. It is therefore contemplated that the appended claims shall cover any such modifications or variations of the described embodiments as falling within the true spirit and scope of the present invention. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to water treatment systems, and more particularly to bypass valves for the water treatment apparatus and sensors for measuring water flow through the treatment system.
2. Description of the Related Art
A water treatment system, such as a water softener or reverse osmosis filter, often is incorporated into the plumbing of a building. For example, potable water received from a well usually is considered to be “hard” as containing minerals that adversely affect the cleansing ability of soaps and detergents. Furthermore, the minerals leave objectionable deposits on plumbing fixtures, glassware and the like. As a consequence, a water softener or filter is employed to remove the minerals and “soften” the water.
Occasionally, it is necessary to perform maintenance on the water treatment system, such as replacing the filter medium or a failed component. In order to perform such maintenance, the water treatment apparatus must be functionally and sometimes physically disconnected from the building's plumbing system. However, while the maintenance is being performed, it is desirable to provide untreated water for use in the building for drinking, flushing toilets and other purposes. Therefore, a bypass valve is provided at the connection of the water treatment apparatus to the building plumbing system. The bypass valve disconnects both the inlet and the outlet of the treatment apparatus from the plumbing pipes and interconnects those pipes so that water is provided throughout the building while the maintenance is being performed.
Flow sensors, such as a turbine wheel connected to a transducer that produces an electric signal, have been incorporated into previous water treatment systems to indicate the amount of water flowing there through. The flow indicating signal is applied to a controller which provides a cumulative measurement of the volume of water that has been treated by the system, thereby indicating when maintenance on the water treatment system needs to be performed or in the case of a water softener when regeneration is required. Heretofore the flow sensors were either incorporated into the main control valve assembly of the water treatment apparatus or were in a separate housing that was placed in a pipe remote from water treatment apparatus. However, such remote location required additional plumbing connections and thus increased the labor costs and component costs associated with the water treatment system.
SUMMARY OF THE INVENTION
A bypass valve for a water treatment system includes a body having a first chamber and a second chamber connected by a bridge passage to the first chamber. The body also comprises an inlet that opens into the first chamber to receive untreated water, an untreated water outlet that opens into the first chamber, a treated water inlet that opens into the second chamber, and an outlet that opens into the second chamber and through which treated water exits the valve.
A first valve element is rotatably received in the first chamber. In a first position, the first valve element connects the inlet to the untreated water outlet. In a second position of the first valve element, the inlet is connected to the bridge passage and disconnected from the untreated water outlet. A second valve element is rotatably received in the second chamber. In a third position, the second valve element connects the outlet to the treated water inlet. In a fourth position of the second valve element, the outlet is connected to the bridge passage and disconnected from the treated water inlet. A manually operable mechanism is provided to rotate the first valve element in the first chamber and the second valve element in the second chamber.
Another aspect of the present bypass valve is the incorporation of a flow sensor into the first or second valve element. Preferably, a turbine is rotatably received in that valve element and a transducer produces an electrical signal in response to rotation of the turbine.
DESCRIPTION OF THE OF THE DRAWINGS
FIG. 1 is an isometric view of a bypass valve according to the present invention;
FIG. 2 is an elevational view of a side of the bypass valve to which connections to the building plumbing system are made;
FIG. 3 is a cross section view through one of the cap assemblies on the bypass valve;
FIG. 4 is an exploded view illustrating the components of the bypass valve;
FIG. 5 is a horizontal cross-sectional view through the assembled bypass valve in the water treatment service position;
FIG. 6 is a horizontal cross-sectional view through the assembled bypass valve in the bypass position; and
FIG. 7 is a horizontal cross-sectional view through the assembled bypass valve in the closed position.
DETAILED DESCRIPTION OF THE INVENTION
With initial reference to FIG. 1 , a bypass valve 10 is provided to functionally disconnect a water treatment apparatus from the plumbing system of a building while still permitting water to be supplied throughout the building. The bypass valve 10 comprises a body 12 with first and second housings 14 and 15 connected by a tubular bridge 16 . The first housing 14 has an inlet 18 adapted for connection to a pipe of the building plumbing system that supplies water to be treated by the water treatment system. A untreated water outlet 20 projects from the first housing 14 diametrically opposite to the inlet 18 . Similarly, the second housing 15 has an outlet 22 projecting from the same side of the bypass valve 10 as the inlet 18 . A treated water inlet 24 is located on the second housing 15 diametrically opposite to the outlet 22 .
The first and second housings 14 and 15 have openings at their tops that are sealed by separate caps 26 and 28 of identical construction. Each cap 26 and 28 threads onto the outer circumferential surface of the respective first or second housing 14 and 15 . The details of the first cap 26 are shown in FIG. 3 . A rubber-sealing ring 39 is located inside the cap to engage the upper annular surface of the first respective housing 14 to prevent water from leaking there between. The first cap 26 has an aperture 30 centrally located in its dome through which a shaft 32 of a valve operator 34 extends. The upper end of the shaft 32 is connected to a member, such as a knob 36 or lever, which can be grasped and turned by a user to operate the bypass valve. The inner end of the actuator shaft 32 is affixed to a disk-shaped driver 38 .
Referring to FIG. 4 , the first housing 14 has a first chamber 41 into which the inlet, untreated water outlet and a passage 55 through the bridge 16 open. The second housing 15 has a second chamber 43 into which the outlet, treated water inlet and the bridge passage 55 open. Identical tubular first and second valve elements 40 and 42 are received respectively within the first and second chambers 41 and 43 . Each element 40 and 42 has an elongated first aperture 44 that extends approximately 150 degrees around its curved outer surface. A circular second aperture 46 is located through that outer surface diametrically opposed to one end of the first aperture 44 . A sealing ring 48 is received in an annular groove in the valve element's outer surface at a center-to-center spacing of 90 degrees from the second aperture 46 .
A flow meter cage 60 is inserted into the tubular second valve element 42 . Openings in the flow meter cage 60 align with the first and second apertures 44 and 46 allowing water to flow through both the second valve element 42 and the flow meter cage. The flow meter cage 60 has a cross member 61 that bows outward into a notch 63 in the driver 38 of the valve operator 34 shown in FIG. 3 so that rotation of the valve operator, as will be described, also rotates the flow meter cage. The cross member 61 fits tightly into the driver's notch so that the flow meter cage 60 is pulled out of the second valve member when the second cap 28 is removed from the second housing 15 .
A disk shaped turbine 62 is rotatably received within the flow meter cage 60 and spins therein under the flow of fluid through the second housing 15 . A permanent magnet 64 is mounted on the turbine 62 . A Hall effect sensor 66 is mounted on the bottom surface of the second housing 15 as shown in FIG. 2 and acts as a transducer producing an electrical signal pulse each time the permanent magnet 64 passed that sensor. Thus the electrical signal pulses can be counted by a conventional circuit in a well-known manner to produce a measurement of the amount of water flowing through the bypass valve.
Referring again to FIG. 4 , the upper edges of the first and second valve elements 40 and 42 , in the illustrated orientation, has a key 50 , which is received within a recess 52 in the edge of the actuator driver 38 beneath its associated cap 26 or 28 , as shown in FIG. 3 . This engagement causes the valve element to rotate within the respective housing 14 or 15 when a user rotates the knob 36 or 37 on the associated cap 26 or 28 . However, when a cap 26 or 28 is removed from the top of the respective first or second housing 14 or 15 , the key 50 slides easily out of the recess 52 , allowing the associated first or second valve element 40 or 42 to remain in the housing.
When the two knobs 36 and 37 are rotated into the position shown in FIG. 1 , the first and second valve elements 40 and 42 are rotated into a “service” position depicted in FIG. 5 . At this time, the first valve element 40 is in a first position and the second valve element 42 is in a third position. Here the first aperture 44 of the first valve element 40 communicates with the inlet 18 and the second aperture 46 in that valve element aligns with the untreated water outlet 20 , thereby conveying fluid from the water supply to the water treatment apparatus. In this state of the bypass valve 10 , the first aperture 44 of the second valve element 42 communicates with the treated water inlet 24 and that valve element's second aperture 46 opens into the bypass valve outlet 22 . Thus fluid is conveyed from the treated water inlet 24 to the bypass valve outlet 22 . The flow of that fluid is measured by the turbine 62 and the associated Hall effect sensor 66 . Note that a solid portion of the second valve element 42 closes a fluid passage 55 through the bridge 16 , thereby preventing water from flowing between the first and second housings 14 and 15 .
When the knobs 36 and 37 are rotated counter-clockwise 90 degrees from the orientation shown in FIGS. 1 and 5 , the first and second valve elements 40 and 42 are rotated the same amount into the “bypass” position shown in FIG. 6 . Now, the first valve element 40 is in a second position and the second first valve element 42 is in a fourth position. In this orientation, the first aperture 44 of the first valve element 40 communicates with both the inlet 18 and the bridge passage 55 . A solid portion of the first valve element 40 closes the untreated water outlet 20 . The two apertures 44 and 46 of the second valve element 42 communicate with the bridge passage 55 and the outlet 22 . The solid portion of the second valve element 42 closes the treated water inlet 24 . Thus in the “bypass” position, water from the inlet 18 is conveyed through the bridge passage 55 directly to the outlet 22 so that untreated water is supplied to the building. The water flows around the turbine 62 which thus does not spin in the bypass position. In this state, both of the water treatment apparatus connections 20 and 24 are closed so that the apparatus can be repaired or have maintenance performed on it.
If from the “service” position shown in FIG. 5 , the knobs 36 and 37 are rotated clockwise 90 degrees, the first and second valve elements 40 and 42 are rotated counter-clockwise by that amount into the closed positions shown in FIG. 7 . Now, the first valve element 40 is in a fifth position and the second first valve element 42 is in a sixth position. In this state, solid portion of the first valve element 40 closes the bypass valve inlet 18 and the solid portion of the second valve element 42 closes the outlet 22 . Now, not only is the water treatment apparatus disconnected from the plumbing pipes connected to the inlet 18 and the outlet 22 , but water is prevented from flowing through the bypass valve 10 between the inlet and the outlet. As a consequence in this state, the bypass valve is fully closed as no fluid can flow through it.
The fully closed state allows a cap 26 or 28 and internal components of the bypass valve to be removed for maintenance. With reference to FIGS. 3 and 4 , the tight fit of the cross member 61 on the flow meter cage 60 into the notch 63 of the driver 38 pulls the flow meter cage and turbine 62 out of the second valve member when the second cap 28 is removed from the second housing 15 . However, the tight engagement of the first and second valve elements 40 and 42 with the inside surface of the respective first and second housings 14 and 15 , provided by each sealing ring 48 , retains the valve elements in those housings and maintains closure of the associated inlet or outlet 18 or 22 .
The foregoing description was primarily directed to a preferred embodiment of the invention. Although some attention was given to various alternatives within the scope of the invention, it is anticipated that one skilled in the art will likely realize additional alternatives that are now apparent from disclosure of embodiments of the invention. Accordingly, the scope of the invention should be determined from the following claims and not limited by the above disclosure. | 4y
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TECHNICAL FIELD
The present invention relates to a method for making laminate materials, and more particularly the present invention relates to a method for making laminate materials having a capillary zone or passageway to acquire, move and/or store fluid within the laminate material. Such laminate materials are particularly suitable for use as a topsheet, an acquisition layer and/or an absorbent core in absorbent articles such as disposable diapers, catamenials, sanitary napkins, bandages, incontinent briefs and the like.
BACKGROUND OF THE INVENTION
It has long been known in the disposable absorbent article art that it is extremely desirable to construct absorptive devices such as disposable diapers, catamenials, sanitary napkins, bandages, incontinent briefs, and the like, presenting a dry surface feel to the user to improve wearing comfort and to minimize the development of undesirable skin conditions due to prolonged exposure to moisture absorbed within the article.
Recently, capillary laminate materials comprised of at least two layers or sheets having a capillary zone between the sheets have been developed to address this previously unmet consumer need. The capillary zone between the sheets is established and maintained by at least one spacer element which simultaneously holds the two layers apart and keeps them from separating further. In a preferred embodiment the capillary laminate material includes a plurality of spacer elements. At least one of the sheets is fluid pervious to allow entry of fluid into the capillary zone. All layers may be rendered fluid-pervious, and such materials may include more than two layers as well. Capillary laminate materials of this variety are described in greater detail in commonly-assigned U.S. patent applications Ser. Nos. 08/212,487, filed Mar. 14, 1994 in the names of Langdon, et al., and 08/442,717, filed May 15, 1995 in the names of Langdon, et al., the disclosures of which are hereby incorporated herein by reference.
SUMMARY OF THE INVENTION
The present invention provides a process for forming a three-dimensional, macroscopically-expanded capillary laminate web comprised of a first sheet of polymeric material and a second sheet of polymeric material. The first sheet is fluid pervious, and the first sheet and the second sheet are spaced apart from one another by a plurality of spacers to define a capillary zone therebetween for the capillary movement of fluid. The first and second sheets are fed onto a first forming structure having opposed surfaces such that the second sheet is in contact with the first forming structure and the first sheet is in contact with the second sheet. At least one of the sheets, preferably the second sheet, has a plurality of spacers on the side facing the other sheet. The first forming structure exhibits a multiplicity of apertures which place the opposed surfaces of the first forming structure in fluid communication with one another. A fluid pressure differential is applied across the thickness of the first and second sheets which is sufficiently great as to cause the first and second sheets to rupture in those areas coinciding with the apertures in the first forming structure and to conform with the first forming structure.
In a preferred embodiment of the process of the present invention, the first sheet is rendered fluid pervious prior to feeding the first sheet onto the second sheet by feeding the first sheet onto a second forming structure. The second forming structure exhibits a multiplicity of apertures which place the opposed surfaces of the second forming structure in fluid communication with one another. A fluid pressure differential is applied across the thickness of the second sheet which is sufficiently great as to cause the second sheet to rupture in those areas coinciding with the apertures in the second forming structure and to conform with the second forming structure.
In another preferred embodiment of the process of the present invention, a second fluid pressure differential is applied to the second sheet after the second sheet is fed onto the forming structure but before the first sheet is fed onto the second sheet.
In still another preferred embodiment of the process of the present invention, the first and second sheets are pre-wound together onto a supply roll with the spacer elements therebetween, and simultaneously fed onto the forming structure.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the accompanying drawings, in which like reference numbers identify like elements throughout the drawings, and wherein:
FIG. 1 is a cut-away view of a preferred embodiment of a capillary laminate film;
FIG. 2 is an enlarged, partially segmented, perspective illustration of a preferred embodiment of the capillary laminate film of FIG. 1, which has been formed into a macroscopically-expanded, three-dimensional laminate material by the methods of the present invention;
FIG. 3 is a cross-sectional view of another preferred embodiment of a capillary laminate film;
FIG. 4 is a simplified schematic illustration of a preferred process according to the present invention for forming capillary laminate materials;
FIG. 5 is a simplified schematic illustration of another preferred process according to the present invention for forming capillary laminate materials; and
FIG. 6 is a simplified schematic illustration of another preferred process according to the present invention for forming capillary laminate materials.
DETAILED DESCRIPTION OF THE INVENTION
While the present invention will be described in the context of producing capillary laminate materials particularly suited for use in disposable absorbent articles, more particularly in the context of sanitary napkins, the present invention is in no way limited to such applications. To the contrary, the present invention may be practiced to great advantage whenever it is desired to produce capillary laminate materials not previously obtainable using prior art web forming processes.
Capillary Laminate Materials.
FIG. 1 depicts a representative capillary laminate material 40 of the type described in the aforementioned Langdon, et al. applications. Capillary laminate material 40 is particularly well suited for use as a topsheet or acquisition layer in a sanitary napkin or other absorbent article. Capillary laminate material 40 shown in FIG. 1 comprises a first fluid pervious sheet or layer 42 and a second fluid pervious sheet or layer 46. The fluid pervious nature of the first sheet 42 and the second sheet 46 is provided by apertures 43 and 47, respectively. While the fluid pervious nature of the first and second sheets 42 and 46 is provided by apertures 43 and 47, it would be obvious to one of ordinary skill in the art that there are other means of imparting a fluid pervious nature to a sheet, such as microporous materials, porous material, slits, etc. The first and second sheets are spaced apart from one another by a spacer. The spacer shown in FIG. 1 comprises a plurality of generally cylindrical spacers 48. Spacers 48 also serve to connect or secure the first sheet 42 to the second sheet 46. Spacers 48 separate first sheet 42 from second sheet 46 such that a "capillary zone" 50 is created between the first sheet 42 and the second sheet 46. As used herein, the term "capillary zone" refers to the space between two adjacent sheets not being occupied by a spacer.
The material selected for the first sheet 42 and the second sheet 46 is preferably machinable and capable of being formed into a sheet. Since the capillary laminate material 40 is to be used in consumer products which contact the human body, the capillary laminate material 40 is preferably soft and safe for epidermal or other human contact. Preferred materials for the first sheet 42 and the second sheet 46 are polymeric materials including, but not limited to polyolefins, particularly polyethylenes, polypropylenes and copolymers having at least one olefinic constituent. Other polymeric materials such as polyester, nylon, copolymers thereof and combinations of any of the foregoing may also be suitable. While first sheet 42 and second sheet 46 are shown as a film, the sheets may, if desired, be in the form of a nonwoven, microporous membrane, foam, etc.
If desired, conventional amounts of agents may also be added to the polymeric matrix of the first sheet 42 and the second sheet 46. It is often desired to add agents to increase the opacity of the sheets. Whiteners, such as titanium dioxide and calcium carbonate may be used to opacity the first and second sheets, 42 and 46, respectively. It may also be desired to add other agents such as surfactants to impart a hydrophilic nature to either the first sheet 42 or the second sheet 46. Degrees and amounts to which agents including whiteners and surfactants are added to the first sheet 42 and the second sheet 46 may be distinct from one another to provide varying effects such as hydrophilicity gradients and the ability to mask fluids within the absorbent article.
The first sheet 42 and the second sheet 46 may themselves be multilayer polymeric films such as those disclosed in commonly assigned U.S. Pat. No. 5,006,394 issued to Baird on Apr. 9, 1991 and U.S. Pat. No. 5,261,899 issued to Visscher et al. on Nov. 16, 1993, said patents being incorporated herein by reference.
The spacers used to form the capillary laminate can be formed from a material which is added to the sheets or from one of the sheets themselves. Examples of materials that can be added include, but are not limited to hot melt adhesives, pressure sensitive adhesives, thermoplastics with a melting point temperature lower than one or more of the sheets, etc. These additional materials can be applied by gravure printing, screen printing or any number of processes which are known to those skilled in the art.
Accordingly, the spacers 48 may be made from any material suitable for securing the first sheet 42 to the second sheet 46. For example, spacers 48 may be made from a heat sealable hot melt adhesive such as Eastobond A3, manufactured by Eastman Chemical, or HL-1412, manufactured by Fuller Adhesive. The spacers 48 may also be made from a polymer material having a lower melting point temperature than the polymeric material used for either the first sheet 42 or the second sheet 46.
The spacers 48 are preferably applied to one of the sheets using a known technique such as gravure printing, screen printing, or transfer printing. When using a pressure sensitive adhesive sufficient pressure must be applied to achieve bonding or securement between the spacers and the respective sheets. When using a hot melt adhesive or a polymeric material having a lower melting point temperature than the materials used for either the first sheet or the second sheet, sufficient heat must be applied to heat the spacers to achieve bonding between the respective sheets.
Alternatively, the spacers 48 may be formed from one or more of the sheets themselves. This can be achieved by embossing, either hot or cold, casting or other processes known to those skilled in the art. The other sheet is then combined with the embossed or cast sheet to form the laminate material of the present invention.
When used as a topsheet on an absorbent article, such as a topsheet on a sanitary napkin, the first sheet 42 becomes the wearer-contacting or body surface of the topsheet. The second sheet 46 becomes the garment facing or pad-contacting surface of the topsheet. Accordingly, as fluid impinges capillary laminate material 40 it first contacts the wearer-contacting surface 42a of the first sheet 42. Fluid then proceeds through apertures 43 and into the capillary zone 50. Upon reaching capillary zone 50 fluid then moves within the capillary zone 50 under capillary pressure. The fluid moves throughout the capillary zone 50 in both the lateral and transverse directions. Simultaneously, the fluid passes through apertures 47 in second sheet 42 and into the acquisition layer of a sanitary napkin.
The dimensions of apertures 43 and 47 in first sheet 42 and second sheet 46, respectively, may be substantially identical to one another or may be of different dimensions. For example, successively smaller apertures in adjacent sheets can be used to create a capillary driving force through the capillary laminate material in the direction of the smaller apertures. When used as a topsheet or an acquisition layer, it may be desirable to have apertures 43 slightly larger than apertures 47 to provide a capillary gradient within capillary laminate material 40. It may also be desirable to vary the dimension of the apertures 43 and 47 within their respective sheets. For example, when used as a topsheet it may be desirable to have the apertures 43 in first sheet 42 which are located in the central region of the sanitary napkin, i.e., the region surrounding the intersection of the longitudinal and transverse centerlines, larger than the apertures adjacent the periphery of the sanitary napkin. The difference in dimension may be easily defined from one region to the next, or may be indiscernible as the dimensions may change gradually from one region to the next region.
In addition to varying the size of apertures 43 and 47 it is also possible to vary the frequency of apertures 43 and 47. For example, when used as a topsheet it may be desirable to have a relatively high frequency of apertures near the central region as compared to the regions near the periphery of the absorbent article. In general, the fewer the apertures and the smaller the apertures the larger the capillary zone defined by the two sheets and the spacers.
The dimension of the capillary zone 50 may be also be varied for particular uses. For example, if used as a topsheet on a disposable diaper, the dimension of capillary zone 50 may be smaller than if used as a topsheet on a sanitary napkin, due to the viscosity and density differences of urine and menses and/or blood. Therefore, the capillary zone for a diaper topsheet will more than likely be smaller than the capillary zone of a sanitary napkin topsheet.
The spacer elements used to both separate and secure the sheets of the capillary laminate material together can be a single spacer or a plurality of spacers having various geometric shapes. The height of the spacers will determine the gap between the sheets or the capillary zone. The capillary zone can be designed to optimally handle different fluids. For example, it has been determined that for blood or menses, the capillary zone should be less than about 0.006 inches (6 mils), more preferably about 0.003 inches (3 mils). Water or urine is best transferred by a smaller capillary zone. The capillary zone may be varied throughout the capillary laminate material. Variability of the capillary zone can be used to encourage fluid flow in the direction of decreasing capillary zone.
The frequency, cross-sectional area, and height of spacers 48 determine to a substantial degree the dimension of the capillary zone 50. The cross-sectional area of the spacers 48 is determined by taking the cross-sectional area of the spacers in a plane substantially parallel to the first and second sheets 42 and 46, respectively, as is indicated by sectional lines A--A in FIG. 1. Spacers 48 are shown as having a circular cross-sectional shape, however, other cross-sectional shapes such as squares, rectangles, ovals, triangles, arcs, dog bone, etc. may also be used for spacers 48.
The sidewalls 49 of spacers 48 are shown as being substantially straight along their length in FIG. 1. However, sidewalls 49 may be concave or convex or any other shape such as sloped, curvilinear, etc. as may be desired.
The spacers may also be used to divide the capillary zone into capillary channels. Capillary channels can be utilized to direct flow within the capillary zone. The capillary channels can be linear, curvilinear or a combination of both. The capillary channels can be uniform in cross-sectional area or they can vary along their length. For example, a decreasing cross-sectional area of a capillary channel can promote fluid flow in the direction of decreasing cross-sectional area.
Within capillary zone 50 there is at least one and more preferably a multiplicity of capillary channels, generally designated as 60. Referring to FIG. 1, as fluid moves between adjacent spacers 48 the shape of the capillary channel 60 between spacers 48 continually changes. Accordingly, the capillary channels 60 have a non uniform shape along their length.
The capillary channels within the capillary zone may take on any shape as desired. For example, the capillary channels may be straight along their entire length, straight along only a portion of their length, continuous along their entire length, discontinuous along their entire length, curvilinear, extend in a fan-like array, oval, hourglass, dog bone, asymmetric, etc.
FIG. 2 is an enlarged, partially segmented, perspective illustration of another preferred embodiment of the capillary laminate film of FIG. 1, which has been formed into a macroscopically expanded, three-dimensional, fiber-like, apertured web 70. The overall form/shape of the macroscopically expanded web 70 is generally in accordance with the teachings of commonly assigned U.S. Pat. No. 4,342,314, issued to Radel et al. on Aug. 3, 1982 and hereby incorporated herein by reference. Web 70 has been found suitable for use as a topsheet on a sanitary napkin. The term "macroscopically expanded", when used to describe three-dimensional webs of the present invention, refers to webs, ribbons, and films which have been caused to conform to the surface of a three-dimensional forming structure so that both surfaces thereof exhibit a three-dimensional pattern of surface aberrations corresponding to the macroscopic cross-section of said forming structure. The surface aberrations comprising said pattern being individually discernible to the normal naked eye, i.e., a normal naked eye having 20/20 vision unaided by any instrument that changes the apparent size or distance of an object or otherwise alters the visual powers of the eye, when the perpendicular distance between the viewer's eye and the plane of the web is about 12 inches. The term "fiber-like" as utilized herein to describe the appearance of webs of the present invention, refers generally to any fine-scale pattern of apertures, random or non-random, reticulated or non-reticulated, which connotes an overall appearance and impression of a woven or non-woven fibrous web when viewed by the human eye.
As can be seen in FIG. 2, the webs fiber-like appearance is comprised of a continuum of fiber-like elements, the opposed ends of each of the fiber-like elements are interconnected to at least one other of the fiber-like elements. In the embodiment disclosed in FIG. 2, the interconnected fiber-like elements form a pattern network of pentagonally shaped capillaries 72. The web 70, which exhibits a fiber-like appearance, embodies a three-dimensional microstructure extending from the web's uppermost or wearer-contacting surface 75 in plane 76 to its lowermost or absorbent pad-contacting surface 78 in plane 79 to promote rapid fluid transport from the uppermost surface 75 to the lowermost surface 78 of the web without lateral transmission of fluid between adjacent capillaries 72. As utilized herein, the term "microstructure" refers to a structure of such fine scale that its precise detail is readily perceived by the human eye only upon magnification by a microscope or other means well-known in the art.
Apertures 85 are formed by a multiplicity of intersecting fiber-like elements, e.g., elements 86, 87, 88, 89 and 90, interconnected to one another in the first surface of the web. Each fiber-like element comprises a base portion, e.g., base portion 92, located in plane 76. Each base portion has a sidewall portion, e.g., sidewall portions 93, attached to each edge thereof. The sidewall portions 93 extend generally in the direction of the second surface 78 of the web. The intersecting sidewall portions of the fiber-like elements are interconnected to one another intermediate the first and the second surfaces of the web and terminate substantially concurrently with one another in the plane 79 of the second surface.
In a particularly preferred embodiment, the interconnected sidewall portions terminate substantially concurrently with one another in the plane of the second surface to form apertures in the second surface 78 of the web. The network of capillaries 72 formed by the interconnected sidewall portions allows for free transfer of fluid from the first surface of the web directly to the second surface of the web without lateral transmission of the fluid between the adjacent capillaries.
In addition, small amounts of fluid are able to penetrate the apertures 43 in the first layer 42 of the capillary laminate material 40. The first layer 42 is separated from and secured to the second layer 46 by spacers 48 to provide a capillary zone 50 between the first and second sheets. Alter penetrating apertures 43, fluid will then move through the capillary zone 50 toward the second surface of the web. Upon reaching the second surface of the web, fluid will be removed from the capillary zone 50 and transmitted to the underlying layer. Fluid may also enter apertures 47 in the second layer 46.
In FIG. 3 there is shown another preferred embodiment of a capillary laminate material 40 of the present invention. Capillary laminate material 40 comprises a first sheet 42 and a second sheet 46 secured together and spaced apart by a plurality of spacers 48. First sheet 42 includes a plurality of apertures 343. The second sheet 346 is substantially non-apertured, thus preventing fluids from transmitting therethrough. Capillary laminate material 40 may be particularly useful as a macroscopically expanded topsheet such as that shown in FIG. 2 where it is not desired or necessary to have fluid penetrate the second sheet 46. Alternatively, the capillary laminate material 40 may also be used as an absorbent core wherein the second sheet 46 is impervious to liquids and therefore may aid the backsheet in the protection against soiling of undergarments and clothing.
Methods of Making Capillary Laminate Materials.
FIG. 4 is a simplified, schematic flow diagram of a process according to the present invention for producing capillary laminate materials, in particular, three-dimensional, macroscopically expanded capillary laminate materials. A web of substantially planar film 101 comprised of a polymeric material such as polyethylene is fed from supply roll 100 around idler roll 105 and onto the surface of forming drum 110 about which a forming structure 111 continuously rotates at substantially the same speed as the incoming web. The web of film is driven by the forming drum 110. The web 101 contains at least one spacer, and preferably contains a plurality of spacers, on the side facing away from forming drum 110 and is of the general configuration of sheet 46 as discussed above with regard to FIG. 3.
Forming structure 111 comprises a macroapertured surface, such as a patterned network of pentagonally-shaped capillaries, and is preferably constructed generally in accordance with the teachings of U.S. Pat. No. 4,342,314, issued to Radel and Thompson on Aug. 3, 1982, the disclosure of which is hereby incorporated herein by reference. Forming structure 111 is comprised of a plurality of individual photoetched lamina. The apertures in forming structure 111 may be of any desired shape or cross-section when the forming structure is fabricated using the laminar construction techniques generally disclosed in the aforementioned patent.
A second web of substantially planar film 116 comprised of a polymeric material such as polyethylene is fed from supply roll 115 around idler roll 120 and onto the surface of forming drum 125 about which a forming structure 126 continuously rotates at substantially the same speed as the incoming web. The web of film is driven by the forming drum 125.
Forming structure 126 comprises a microapertured surface, such as a woven wire support member, which rotates about a stationary vacuum chamber 135, generally in accordance with the teachings of U.S. Pat. Nos. 4,629,643 and 4,609,518, the disclosures of which are hereby incorporated herein by reference. A high pressure liquid jet nozzle 130 is directed at the surface of the web 116 intermediate a pair of baffles (not shown) as the web traverses the vacuum chamber 135. The high pressure, i.e., preferably at least about 800 psig., jet of liquid causes the web 116 to assume the general contour of the knuckle pattern of the woven wire support member 126. In addition, because the interstices formed by the intersecting filaments are unsupported, the fluid jet causes rupture at those portions of web 116 coinciding with the interstices in the woven wire support structure 126, thereby producing a "microapertured" web. This microapertured web exhibits a multiplicity of fine scale surface aberrations with microapertures coinciding with the point of maximum amplitude of the surface aberrations. The structure and formation of such microapertured webs is described in greater detail in the above-referenced and incorporated U.S. Patents.
After the microaperturing process is completed, the microapertured web is removed from forming structure 126 about an idler roll 140, passed about an idler roll 145, and applied to the outwardly-facing surface (containing the spacers) of the web 101 which was previously applied to the forming structure 111. Alternatively, the forming structures 110 and 125 may be positioned in closer proximity to one another, such that the idler rolls 140 and 145 may be omitted. The microapertured web, when produced by the above-described method, is preferably oriented such that the microscopic surface aberrations are oriented so as to face outwardly away from the forming structure 111.
The forming drum 110 preferably includes an internally located vacuum chamber 155 which is preferably stationary relative to the moving forming structure 111. A pair of stationary baffles (not shown) approximately coinciding with the beginning and end of the vacuum chamber 155 are located adjacent the exterior surface of the forming structure. Intermediate the stationary baffles there is preferably provided means for applying a fluid pressure differential to the laminate web 175 as it passes over the vacuum chamber. In the illustrated embodiment, the fluid pressure differential applicator means comprises a high-pressure liquid nozzle 150 which discharges a jet of liquid, such as water, substantially uniformly across the entire width of web 101. Examples of methods for the production of formed materials using a high-pressure liquid stream are disclosed in U.S. Pat. Nos. 4,695,422, issued to Curro et al. on Sep. 22, 1987; 4,778,644, issued to Curro et al. on Oct. 18, 1988; and 4,839,216, issued to Curro et al. on Jun. 13, 1989, the disclosures of all of these patents being hereby incorporated herein by reference.
The water jet causes the web 101 to conform to the forming structure 111 and apertures the web 101 in the areas coinciding with the capillaries in forming structure 111. In some situations, it may be preferable to heat the liquid stream to cause thermal bonding between the spacers and the second web 116 to form the laminate web 175. The pressure of the liquid stream is preferably selected so as to achieve sufficient conformity of the web to the forming structure without collapsing the capillary zone between the webs or sheets, or compromising the integrity of the sheets themselves.
As an alternative embodiment, it may be desirable to provide an additional high-pressure liquid nozzle 165 and vacuum chamber 170 analogous to nozzle 150 and chamber 155, respectively, to cause the incoming web 101 to conform to the surface of the forming structure 111 before the second incoming web 116 is applied. Such an arrangement may improve the processability and quality of the finished laminate material by pre-forming the first web and reducing the force required to form the laminate as a whole.
Following application of the fluid pressure differential to the web, the three-dimensional, macroscopically-expanded, apertured laminate web 175 is removed from the surface of the forming structure 111 about an idler roll 160 in the condition shown in FIG. 2. The apertured laminate web 175 may be utilized without further processing as a topsheet in an absorbent article. Alternatively, the apertured laminate web 175 may be subjected to further processing, such as ring rolling, creping, or surface treatment as may be desired.
The resulting laminate web 175 exhibits the general overall configuration of FIG. 2, with the upper sheet being fluid pervious and the lower sheet being fluid-impervious, as depicted in FIG. 3. If a laminate web with both sheets being fluid pervious is desired, such as depicted in FIG. 1, the lower sheet may be apertured prior to lamination by the method disclosed above with regard to the upper sheet, or by any other suitable method, so as to assume the configuration of sheet 46 of FIG. 1.
FIG. 5 is a simplified schematic diagram of another preferred process according to the present invention for producing capillary laminate webs. A co-wound web of substantially planar film comprised of a polymeric material such as polyethylene, spacer element or elements, and microapertured planar film comprised of a polymeric material such as polyethylene, is fed from supply roll 200 around idler roll 205 and onto the surface of forming drum 210 about which a forming structure 211 continuously rotates at substantially the same speed as the incoming web. It may be desirable to pre-bond the first and second webs or sheets to one another before or during the pre-winding of the supply roll 200. The web of film is driven by the forming drum 210. The web 201 is oriented such that the microapertured web faces away from the forming structure 211, and is of the general configuration of sheet 46 as discussed above with regard to FIG. 3. The microapertured web may be produced by the method described above with regard to FIG. 4 or any other suitable method, and if produced as described above is preferably oriented with the microscopic surface aberrations facing away from the other film components and away from forming structure 211.
Forming structure 211 is generally similar to the forming structure 111 shown in FIG. 4, and comprises a macroapertured surface, such as a patterned network of pentagonally-shaped capillaries. As before, the apertures in forming structure 211 may be of any desired shape or cross-section when the forming structure is fabricated using the laminar construction techniques generally disclosed with regard to FIG. 4.
The forming drum 210 preferably includes an internally located vacuum chamber 220 which is preferably stationary relative to the moving forming structure 211. The structure and operation of the forming drum 210 is substantially as described above with regard to forming drum 110 depicted in FIG. 4. In the illustrated embodiment, the fluid pressure differential applicator means comprises a high-pressure liquid nozzle 215 which discharges a jet of liquid, such as water, substantially uniformly across the entire width of web 201.
The water jet causes the web 201 to conform to the forming structure 211 and apertures the laminate web 230 in the areas coinciding with the capillaries in forming structure 211. In some situations, it may be preferable to heat the liquid stream to cause thermal bonding between the spacers and the second web to form the laminate web 230. The pressure of the liquid stream is preferably selected so as to achieve sufficient conformity of the web to the forming structure without collapsing the capillary zone between the webs or sheets, or compromising the integrity of the sheets themselves.
Following application of the fluid pressure differential to the web, the three-dimensional, macroscopically-expanded, apertured laminate web 230 is removed from the surface of the forming structure 211 about an idler roll 225. The apertured laminate web 230 may be utilized without further processing as a topsheet in an absorbent article. Alternatively, the apertured laminate web 230 may be subjected to further processing, such as ring rolling, creping, or surface treatment as may be desired.
The resulting laminate web 230 exhibits the general overall configuration of FIG. 2, with the upper sheet being fluid pervious and the lower sheet being fluid-impervious, as depicted in FIG. 3. If a laminate web with both sheets being fluid pervious is desired, such as depicted in FIG. 1, the lower sheet may be apertured prior to lamination by the method disclosed above with regard to the upper sheet, or by any other suitable method, so as to assume the configuration of sheet 46 of FIG. 1.
FIG. 6 is a simplified schematic diagram of another preferred process according to the present invention for producing capillary laminate webs. A web of substantially planar film comprised of a polymeric material such as polyethylene is fed from supply roll 300 around idler roll 305 and onto the surface of forming drum 310 about which a forming structure 311 continuously rotates at substantially the same speed as the incoming web. The web of film is driven by the forming drum 310. The web 301 contains at least one spacer, and preferably contains a plurality of spacers, on the side facing away from forming drum 310 and is of the general configuration of sheet 46 as discussed above with regard to FIG. 3.
A second microapertured web of substantially planar film 316 comprised of a polymeric material such as polyethylene is fed from supply roll 315 around idler roll 320 and onto the surface of forming drum 310. The microapertured web may be produced by the method described above with regard to FIG. 4 or any other suitable method, and if produced as described above is preferably oriented with the microscopic surface aberrations facing away from the other film components and away from forming structure 311.
Forming structure 311 is generally similar to the forming structure 111 shown in FIG. 4, and comprises a macroapertured surface, such as a patterned network of pentagonally-shaped capillaries. As before, the apertures in forming structure 311 may be of any desired shape or cross-section when the forming structure is fabricated using the laminar construction techniques generally disclosed with regard to FIG. 4.
The forming drum 310 preferably includes an internally located vacuum chamber 320 which is preferably stationary relative to the moving forming structure 311. The structure and operation of the forming drum 310 is substantially as described above with regard to forming drum 110 depicted in FIG. 4. In the illustrated embodiment, the fluid pressure differential applicator means comprises a high-pressure liquid nozzle 315 which discharges a jet of liquid, such as water, substantially uniformly across the entire width of web 350.
The water jet causes the webs 301 and 316 to conform to the forming structure 311 and apertures the laminate web 350 in the areas coinciding with the capillaries in forming structure 311. In some situations, it may be preferable to heat the liquid stream to cause thermal bonding between the spacers and the second web to form the laminate web 350. The pressure of the liquid stream is preferably selected so as to achieve sufficient conformity of the web to the forming structure without collapsing the capillary zone between the webs or sheets, or compromising the integrity of the sheets themselves.
As an alternative embodiment, it may be desirable to provide an additional high-pressure liquid nozzle 340 and vacuum chamber 345 analogous to nozzle 325 and chamber 330, respectively, to cause the incoming web 301 to conform to the surface of the forming structure 311 before the second incoming web 316 is applied. Such an arrangement may improve the processability and quality of the finished laminate material by pre-forming the first web and reducing the force required to form the laminate as a whole.
Following application of the fluid pressure differential to the web, the three-dimensional, macroscopically-expanded, apertured laminate web 350 is removed from the surface of the forming structure 311 about an idler roll 335. The apertured laminate web 350 may be utilized without further processing as a topsheet in an absorbent article. Alternatively, the apertured laminate web 350 may be subjected to further processing, such as ring rolling, creping, or surface treatment as may be desired.
The resulting laminate web 350 exhibits the general overall configuration of FIG. 2, with the upper sheet being fluid pervious and the lower sheet being fiuid-impervious, as depicted in FIG. 3. If a laminate web with both sheets being fluid pervious is desired, such as depicted in FIG. 1, the lower sheet may be apertured prior to lamination by the method disclosed above with regard to the upper sheet, or by any other suitable method, so as to assume the configuration of sheet 46 of FIG. 1.
Although in the foregoing illustrative process descriptions spacers have been initially provided on the outwardly-facing surface of the web closest to the forming structure, it may be desirable under some circumstances to form or provide the spacers on the inwardly-facing side of the web farthest from the forming structure. It may also be desirable to provide spacers on both webs on their facing surfaces.
In addition, the processes described herein may be adapted and expanded to produce capillary laminate materials having more than two sheets of material, in particular 3 or more sheets with a plurality of spacers between adjacent sheets, to form capillary laminate materials of the types generally described in the aforementioned Langdon et al. U.S. Patent Applications.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to one skilled in the art that there is other changes and modifications that can be made without departing from the spirit and scope of the present invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. | 4y
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TECHNICAL FIELD
[0001] This patent disclosure relates generally to exhaust outlet elbows for natural gas burning turbocharged engines. More particularly, to a connecting structure for connecting the exhaust elbow to an exhaust system.
BACKGROUND
[0002] In areas having cold weather, in particular in the winter, homes require heat to keep the occupants warm. Natural gas is often used as an economical source to generate heat. Natural gas lines may be located in remote areas of the country and require a power source to move the gas in a gas line from point A to point B. Engines, such as turbocharged gas engines may be used as the required power source to move the gas. Turbocharged gas engines are operated at high temperatures and can use natural gas as their fuel source.
[0003] An enclosure can be used to store some or all of the turbocharged gas engine components in order to protect the various components during use. However, the enclosure may achieve undesired high temperatures inside the box during the operation of the turbocharged gas engines.
[0004] Some turbocharged gas engines may incorporate two turbochargers. Exhaust gases from the engine may be routed into the turbochargers and then directed to the exhaust elbow. The exhaust elbow may be subject to high temperatures as result of being exposed to the engine exhaust gases. An apparatus or method for cooling various components of the exhaust elbow may be desirable. An exhaust elbow may be enlarged to accommodate a cooling system. However enlarging the elbow can create complications particularly at places where space is at a premium. Furthermore, it would be desirable to minimize altering attachment points so that an enlarged, replaced elbow having a cooling system can be made to fit within existing systems with respect to both space limitations and current attachment interfaces.
[0005] U.S. Pat. No. 7,185,490 purports to be directed to an exhaust manifold has a head flange constructed for receiving at least two exhaust pipes arranged side-by-side, and includes spaced apart first and second longitudinal flange portions. A mounting assembly is provided for securing the exhaust manifold to a cylinder head of an internal combustion engine in a sealed manor and includes a mounting rail formed with a shoulder which laps over the first longitudinal flange portion and contacts the first longitudinal flange portion in a spring-elastic manner. Plural screw fasteners at least indirectly clamp the second longitudinal flange portion to the cylinder head. However in this patent, the exhaust manifold uses a flange to connect to the engine. At locations where space is at a premium, it would be desirable to have a system and method for attaching a manifold without the use of a flange on the manifold.
SUMMARY
[0006] In some aspects, an exhaust outlet elbow includes: a body having an outer wall and an interior wall, the wall defining, at least in part, an interior chamber; a connecting surface located above the interior chamber; and an array of threaded holes located about the connecting surface, wherein the threaded holes terminate in the body.
[0007] In some aspects, a method of manufacturing an exhaust outlet elbow includes the steps of: forming a body having an outer wall and an interior wall, the interior wall defining, at least in part an interior chamber; forming a connecting surface located between the interior and outer walls; and forming an array of threaded holes in the connecting surface.
[0008] In some aspects, an exhaust outlet elbow includes: a body having an outer wall and an interior wall, the interior wall defining, at least in part, an interior chamber; a connecting surface located above the interior chamber, wherein the connecting surface is located between the interior wall and the outer wall; an array of threaded holes located about the connecting surface, wherein the threaded holes terminate in the body and wherein the holes in the array of threaded holes are equally spaced in a circular pattern and wherein the array of threaded holes are arranged and dimensioned to correspond to holes located in a conduit configured to attach to the connecting surface; and a coolant chamber located in the body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 illustrates a gas line system having turbocharger engines within an enclosure according to an aspect of the disclosure.
[0010] FIG. 2 illustrates a perspective view of the turbocharger engines within the enclosure of FIG. 1 according to an aspect of the disclosure.
[0011] FIG. 3 is a perspective view of an exhaust elbow in accordance with some aspects of the disclosure.
[0012] FIG. 4 is a perspective cross-sectional view of an exhaust elbow in accordance with some aspects of the disclosure.
[0013] FIG. 5 is a top view of exhaust elbow in accordance with some aspects of the disclosure.
[0014] FIG. 6 is a perspective cross-sectional view of an exhaust elbow in accordance with some aspects of the disclosure.
[0015] FIG. 7 is a partial, perspective, cross-sectional view of a portion of the exhaust elbow in accordance with some aspects of the disclosure.
DETAILED DESCRIPTION
[0016] The disclosure relates to a device and method that facilitate the transfer of natural gas from point A to point B. Although turbocharged engines using natural gas as the fuel are discussed herein, the device and method can be used with any type of engine including fossil fueled gasoline engines, and the like in order to prevent undesired temperatures within an enclosure. Further, although two engines are discussed, the device and method can be utilized with more or less engines.
[0017] FIG. 1 illustrates a gas line system 100 with gas line 102 having turbocharged engines within an enclosure 200 according to an aspect of the disclosure. The gas line 102 provides the conduit to transfer natural gas from point A to point B. The turbocharged engines can utilize natural gas from the gas line 102 to operate and transfer natural gas from point A to point B.
[0018] FIG. 2 illustrates a perspective view of portions of the turbochargers 204 within the enclosure 200 of FIG. 1 according to an aspect of the disclosure. The enclosure 200 may be positioned on a base 208 . The enclosure 200 may be formed using a heat shield 202 that is configured and designed to keep heat within the enclosure 200 . Thus, the heat shield may trap so much heat that it may burn the mechanic servicing the enclosure 200 or the trapped heat interferes with the operation of the turbochargers 204 . The heat shield 202 may be constructed using thick sheet metal consisting of an inner wall 210 and an outer wall 206 that form a seal so that fluid may be able to circulate therein between according to an embodiment of the disclosure. By allowing fluid to circulate in between the inner wall 210 and outer wall 206 , the heat shield 202 can be cooled.
[0019] In other embodiments, the heat shield 202 may be made of a material including tin, aluminum, or a composite metal material and the like. The heat shield 202 may be constructed and arranged to house some or all of the components of the turbochargers 204 . Turbochargers 204 are shown in FIGS. 1 and 2 as being positioned mainly on either ends of the heat shield 202 . The components of the turbochargers 204 can be located inside or outside of the heat shield 202 . Alternatively, the heat shield 202 may envelop or house all the components of the turbochargers 204 according to an embodiment of the disclosure. Compressors 212 are also shown positioned outside of the heat shield 202 and having a compressor air outlet 213 . Compressor inlet 214 and exhaust lines 216 of turbochargers 204 are also attached to compressors 212 .
[0020] Also illustrated in FIG. 2 , is a waste gate 218 that is positioned above a fluid cooled exhaust outlet elbow 300 having a cover 301 installed for shipping the enclosure 200 . The cover 301 is attached to the exhaust elbow 300 by bolts 303 . Typically when the exhaust elbow 300 is in use, the cover 301 is removed and a conduit (not shown) is attached to the exhaust elbow 300 . The conduit vents the exhaust gases to an appropriate place of deposit which, in some aspects, maybe the atmosphere.
[0021] The waste gate's 218 function is to bypass some of the exhaust flow around the turbine section of the turbochargers 204 . Exhaust may enter the waste gate 218 through an exhaust outlet 220 . The exhaust can help to prevent over speed of the turbochargers 204 . As noted above, during use the turbochargers 204 can generate a significant amount of heat within the heat shield 202 . By placing the exhaust outlet elbow 300 that is fluid cooled within the heat shield 202 , the exhaust outlet elbow 300 can reduce the ambient temperature within the heat shield 202 . Controlling the ambient temperature within the heat shield 202 may avoid the temperature within the enclosure 200 from reaching undesired levels.
[0022] FIG. 3 illustrates an exhaust outlet elbow 300 in accordance with the present disclosure. The exhaust outlet elbow 300 includes a body 302 . Occasionally, the body 302 may be referred to as a pot or flowerpot 302 . The body 302 is generally made of cast-iron, but, in some aspects the body 302 , may be made of other materials such as cast aluminum, steel, or any other metallic or nonmetallic substance. The body 302 may include a boss 304 . The boss 304 may have a sensor hole 306 for mounting a NOx, Oxygen, temperature, pressure or any other type sensor (not shown). Other holes 308 may also be located on the boss 304 to help secure the sensor in place. One of ordinary skill in the art will understand that the boss 304 and its associated sensor and other holes 306 and 308 are optional.
[0023] The body 302 defines an interior chamber 310 . A divider rib 312 is located in the interior chamber 310 . The divider rib 312 may be cast with, and be integral with, the body 302 . In other aspects, the divider rib 312 may be secured to the body 302 by fasteners, welding, or any other means for attaching the divider rib 312 to the body 302 . The divider rib 312 divides the interior chamber 310 into a first side 314 and a second side 316 . The divider rib 312 may include a free end 313 opposite the portion of the divider rib 312 that attached to the body 302 .
[0024] The divider rib 312 may terminate at one end with a scalloped portion 318 adjacent to a stepped portion 319 attached to, or integral with, an interior wall 320 of the body 302 . In some aspects, the stepped portion 319 and scalloped portion 318 provide a transition between the interior wall 320 and the divider rib 312 . The scalloped portion 318 may include a curved surface curving down from the free end 313 of the divider rib 312 to the stepped portion 319 .
[0025] A first exhaust inlet 321 provides fluid communication through the body 302 and interior wall 320 to the first side 314 of the interior chamber 310 . A second exhaust inlet 323 provides fluid communication from outside of the body 302 , through the body 302 , and interior wall 320 into the second side 316 of the interior chamber 310 . In some aspects, the divider rib 312 is dimensioned and located to provide a barrier from exhaust entering the interior chamber 310 from the first exhaust inlet 321 from flowing through the interior chamber 310 and out the second exhaust inlet 323 and vice versa. In this manner, the divider rib 312 interrupts the flow of exhaust after flowing through the inlets 321 , 323 and forces that exhaust to fill the interior chamber 310 .
[0026] A main or top connecting surface 322 (referred to herein for convenience as a first connecting surface) is located on a top portion of the body 302 . The connecting surface 322 is generally flat and contains an array 324 of holes 326 . In some aspects, the holes 326 are tapped and provide a way to attach a conduit (not shown), cover 301 , or other structures to the body 302 . For example, if it were desired to attach a conduit to the body 302 , the conduit having a flange may be fitted onto the connecting surface 322 and fasteners may extend through a flange in a conduit (not shown) and attach to the body 302 via the threaded or tapped holes 326 .
[0027] In some aspects, a waste gate housing 328 is located on the body 302 . In some aspects, the waste gate housing 328 may be cast with, and be an integral with, the body 302 . In other aspects of the disclosure, the waste gate housing 328 may be attached to the body 302 via fasteners or any other means for attaching the waste gate housing 328 to the body 302 . A second connecting surface 330 is located on the waste gate housing 328 which is attached to or integral with the body 302 . In some aspects, the second connecting surface 330 may be located adjacent to the first connecting surface 322 . The second connecting surface 330 may also contain several connecting holes 332 . In some aspects, these connecting holes 332 may also be tapped to accept and secure fasteners such as bolts. The waste gate 218 may be connected to the waste gate housing 328 via bolts 219 (see FIG. 2 ) fit into the connecting holes 332 . Other holes 333 may be used for connecting other features such as a waste gate heat shield 335 as shown in FIG. 2 .
[0028] In some aspects, particularly in instances where the body 302 is made of a cast material such as cast iron, various freeze plug holes 336 may be located at various locations on the body 302 . The freeze plug holes 336 are an artifact of the manufacturing and casting process and are not particularly relevant to specific aspects described in the claims.
[0029] FIG. 4 is a perspective cross-sectional view of an exhaust elbow 300 . Aspects and features described above with respect to FIG. 3 are also shown in FIG. 4 . For example, FIG. 4 illustrates a body 302 having a boss 304 with a sensor hole 3 . 06 . The interior chamber 310 can be seen along with the divider rib 312 shown in cross-section. The free end 313 of the divider rib 312 can be seen. The interior chamber 310 is divided into a first side 314 and a second side 316 . The scalloped portion 318 and stepped portion 319 can also be seen.
[0030] Hot exhaust gases can enter the interior chamber 310 through the exhaust inlets 321 and 323 and waste gate inlet 344 (only inlets 321 and 344 are shown in FIG. 4 ) and the incoming gases from inlets 321 and 323 contact the divider rib 312 . The exhaust gases exit the body 302 by moving straight up into a conduit (not shown) attached to the connecting surface 322 . Some of the exhaust gases will enter the waste gate housing 328 via waste gate inlet 344 . These gases will also exit the body 302 by moving straight up through the conduit (not shown) attached to the connecting surface 322 . Hole 331 provides an entryway for a poppet valve (not shown) in the waste gate 218 to selectively enter the waste gate housing 328 and seal against the valve seat 345 .
[0031] As one of ordinary skill in the art will appreciate after reviewing this disclosure, the body 302 may become hot as result of being in contact with the exhaust gases. As such, a coolant chamber 346 may be integrated within the body 302 . The coolant chamber 346 may be located between the interior wall 320 and the outer wall 348 of the body 302 . In some aspects, a coolant such as water, glycol, or any other suitable cooling fluid may be present in the coolant chamber 346 . In some aspects, the interior wall 320 may separate the interior chamber 310 from the coolant chamber 346 . At other locations, the interior wall 320 merely separates the interior chamber 310 from outside of the body 302 .
[0032] The coolant chamber 346 may have a coolant inlet 342 and a coolant outlet 334 to allow cooling fluid to flow through the coolant chamber 346 and thereby cool the body 302 . As stated above, the freeze plug holes 336 are an artifact of the manufacturing process and are optional features. Generally, while the elbow 300 is in use, the freeze plug holes 336 are filled with a plug or other material in order to prevent cooling fluid from flowing out of the coolant chamber 346 .
[0033] In some aspects, the rib 312 may include an extended portion 350 that projects into the coolant chamber 346 in order to assist in cooling the rib 312 . The extended portion, 350 allows for more cooling surfaces for the coolant to act on.
[0034] Due to peculiarities of various materials during heating and cooling, certain aspects of the rib 312 may be designed to assist in minimizing thermal stresses due to the expansion and contraction. For example, FIG. 5 illustrates a top of the exhaust outlet elbow 300 . The first connecting surface 322 and array 324 of connecting holes 326 are shown. The rib 312 is located below the first connecting surface 322 and attaches to an interior wall 320 at each end with fillets 340 . In some aspects, the rib 312 is cast along with the body 302 . In such instances, fillets 340 provide a transition between the rib 312 and the interior wall 320 of the body 302 . According to some aspects, each end of the rib 312 , has a scalloped portion 318 and a stepped portion 319 is located between the free end 313 of the rib 312 and the interior wall 320 . The fillets 340 may provide a transfer between the stepped portion 319 and the interior wall 320 .
[0035] FIGS. 3 thorough 5 illustrate the array 324 of the connecting holes 326 . As shown in the FIGS., the threaded connecting holes 326 are not through holes but rather terminate within the body 302 of the elbow 300 . The array 324 may include substantially equally spaced holes 326 in a circular pattern as shown. In some aspects, the array 324 may include 12 tapped holes 326 . In other aspects, other amounts of tapped holes 326 may be included in the array 324 . The array 324 of holes 326 are located in the connecting surface 322 which is located between the interior wall 320 and the outer wall 348 of the elbow 300 . In some aspects of the present disclosure, the first connecting surface 322 may be a substantially flat, annular surface. In some aspects, the array 324 of connecting holes 326 may be arranged, located, and dimensioned to correspond to the attaching holes (not shown) located in a conduit (not shown) configured to attach to the connecting surface 322 . The second connecting surface 330 may also contain connecting holes 332 that are similar to the connecting holes 326 in that the connecting holes 332 may not be through holes but terminate within the body 302 of the exhaust outlet elbow 300 .
[0036] Traditionally, flanges having connecting holes were used rather than having the holes 326 terminate within the body 302 to connect the body 302 to a conduit. The flanges with holes were used because the heat associated with hot exhausts could cause the components such as fasteners, washers, holes, etc. to become so hot that the components would seize within the body 302 making it difficult to change the exhaust conduit (not shown) or remove the body 302 from the conduit. However, in some aspects of the present application, the problem of heat causing the fasteners to seize is addressed by the fact that the cooling chamber 346 extends near the connecting surface 322 as shown in FIG. 6 . The coolant in the cooling chamber 346 can reduce the amount of heat in the connecting surface 322 and any fasteners or bolts 303 located in the tapped holes 326 , and thereby prevent the fasteners 303 from seizing in place. As a result, the location of the cooling chamber 346 extending proximate to the attaching surface 322 allows for the holes 326 to terminate with the body 302 and obviates the need for a flange.
[0037] FIG. 6 is a perspective, cross-sectional view of the exhaust outlet elbow 300 showing the rib 312 having a scalloped portion 318 and the stepped portion 319 . As can be seen in FIG. 6 , the coolant chamber 346 is defined by the outer wall 348 of the body 302 and the interior wall 320 of the body 302 , extends behind the interior wall 320 where the stepped portion 319 meets the scalloped portion 318 of the rib 312 . The scalloped portion 318 may include a curved surface that provides a transition between the free end 313 and stepped portion 319 . Therefore, the free end 313 of the rib 312 is prevented from directly contacting the portion of the interior wall 320 that separates the interior chamber 310 from the coolant chamber 346 .
[0038] In some aspects, it may be desired to prevent the free end 313 of the rib 312 from directly contacting the portion of the interior wall 320 that provides a barrier between the coolant chamber 346 and the interior chamber 310 because a portion of the interior wall 320 may be significantly cooler due to the coolant in the coolant chamber 346 then the free end 313 of the rib. As result of the separation, undue thermal stress on the free end 313 of the rib 312 may be avoided.
[0039] Additional detail of an example of the scalloped portion 318 is illustrated in FIG. 7 . The rib 312 is located in the interior chamber 310 of the body 302 . The scalloped portion 318 of the rib 312 includes a curved surface providing a transition between the free end 313 of the rib 312 and the stepped portion 319 . The coolant chamber 346 located between the outer wall 348 and the interior wall 320 of the body 302 can also be seen.
INDUSTRIAL APPLICABILITY
[0040] As one of ordinary skill the art can appreciate after reviewing this disclosure, exhaust outlet elbows for turbochargers may provide a variety of functions. For example, the exhaust elbow provides a variety of places for the exhaust gases to be diverted. Providing various inlets for the exhaust gases to flow into is one useful feature of the exhaust elbow.
[0041] It is desirable to provide structure within the exhaust outlet elbows to hinder gases entering the exhaust outlet elbow from one turbocharger to flow into the second turbocharger. As such, the divider rib as shown is used to hinder flow of exhaust gases from one turbocharger to the other. Due to the high temperatures of exhaust gases the exhaust elbow itself may become very hot. In order to control or regulate how hot the exhaust elbow gets, coolant may flow through the exhaust elbow through a cooling chamber.
[0042] As one of ordinary skill the art can appreciate after reviewing this disclosure, portions of the exhaust elbow that are in contact with the cooling chamber may be cooler than other aspects of the exhaust elbow not in direct contact with the cooling chamber. Therefore, different aspects of the exhaust elbow may be at very different temperatures. During operation, differences in temperature within the exhaust elbow may be quite large. As a result, it may be desirable to prevent some portions of the exhaust elbow from contacting other portions of exhaust elbow which can be at a greatly different temperature in order to avoid thermal stresses and/or other undesirable effects. In order to provide thermal transitions features, the scalloped portions, fillets, and stepped portions may be used.
[0043] Because of the complex and ever evolving requirements placed upon modern machinery such as exhaust elbows, various improvements to the elbows may be made over time. As such, it may be desirable to maintain various interfaces so that elbows can be removed and replaced within larger machines without having to reconfigure connection points. Therefore, arranging fasteners in standard arrays dimensioned to be the same as former arrays may be desirable. Furthermore, the ability to provide an array of holes that are tapped directly as part of the body enables the body to be of a larger diameter than previous exhaust apparatuses which relied on flanges having holes at various attachment points.
[0044] The many features and advantages of the disclosure are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the disclosure which fall within the true spirit and scope of the disclosure. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the disclosure. | 4y
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SECTOR OF THE TECHNIQUE
[0001] The invention object of the patent fits in the sector of materials intended for the packaging of palletized products, especially for use in the food sector, which, due to its characteristics, need the absence of a heat barrier, either because they need the input of cold, such as in the case of products that need refrigeration or freezing, or because they need the dissipation of heat, preventing condensation.
STATE OF THE ART
[0002] The objective of disposing of micro or macroperforated plastics is to have a resistant material, mainly intended for the packaging of palletizing systems, which enables a optimum ventilation without creating a heat barrier, and reduces the consumption of polymer materials without reducing the mechanical resistance.
[0003] Currently, in order to increase the mechanical resistance of plastic films elaborated by means of diverse punching techniques, and to improve their characteristics, different chemical products are applied or longitudinal reinforcement strips on the edges or washers surrounding the perforations are applied, normally with the input of heat or complex physicochemical processes.
[0004] These currently existing processes present the inconvenience of needing more or less complex techniques that usually require very large devices with high energy consumption.
[0005] Therefore, the objective is to obtain a macroperforated sheet of film by means of the simplest process possible, said sheet of film will be made up by two or more layers of material which, after being punched in a simultaneous manner in a process as the one described in patent application 201030581/7, and, thanks to the sticky texture of the sheet, the film can be handled as a single film that can be pre-stretched and rewound for its use in a conventional packaging system. Due to the foregoing, there is no need to dispose of accumulated material at the edge of the perforation for its later pre-stretching, which allows the elongation suffered to be more uniform in the whole surface of the sheet of film.
DETAILED DESCRIPTION OF THE INVENTION
[0006] The invented sheet of film is made up by two or more sheets of film that are subjected to a mechanical cold punching process in a joint manner. The size, the shape and the disposition of the holes can be modified depending on the applications desired for the final product. In order to obtain this product, a punching and winding system as the one described in the patent-pending invention 201030581/7 is applied, this system consists of feeding plastic film for automatic unwinding, feeding a double roller that rotates simultaneously after the plastic film coils have been fed. One of these cylinders, the punching cylinder, is provided with a set of reliefs, in the desired disposition and shape on its surface. The entire punching equipment is made of tempered steel. When passing through both rollers, the film is subjected to such a pressure that the punching cylinder is able to produce the complete and clean cut of each one of the holes to be made. This pressure can be adjusted as is convenient thanks to a hydraulic pressure gauge system, depending on the material to be punched and its thickness, which allows varying the number of sheets to be perforated simultaneously. Once the sheets of plastic have been punched and the surplus punching material has been removed, the unwinding of the product elaborated in 2, 3 or more layers is carried out in both rollers set at the end of the punching process, said product being manageable as a single multi-layer film.
[0007] The product obtained in this manner can then be subjected to pre-stretching processes with the aim of obtaining a double objective: a significant increase in the output based on length (approximately 300 per cent), which means reducing the consumption of raw materials, the reduction of waste and energy costs; and providing the film with a memory effect, which facilitates holding the loads on the pallet.
[0008] The product obtained in this manner allows a multiplicity of input/output options (i/o), which can consist of: i-input coils o-output coils (i/o), thus obtaining n number of macroperforated multi-layer film output coils, where i and o represent the number of input and output coils, respectively. The most usual combinations are the following: 2 input, 1 output (double sheet); 2 input, 2 output (single sheet); 6 input, 3 output (double sheet); 6 input, 2 output (triple sheet). The combinations obtained in this manner would be practically unlimited and allow obtaining a product whose mechanical resistance can be obtained “à la carte” according to the needs of the material to be packaged, all of the foregoing with a lower weight than that the weight obtained when using non-perforated film or mechanically reinforced perforated film with external elements as indicated above.
DESCRIPTION OF THE DRAWINGS
[0009] A series of drawings describing the process that intend to graphically illustrate the aforementioned manufacturing process accompany the present specification.
[0010] FIG. 1 shows a simplified scheme of the macroperforation process according to patent application 201030581/7, in which the most important parts of the process resulting in the macroperforated film are identified: the untreated plastic coil ( 1 ) is unwound and the film ( 2 ) passes through the feed rollers ( 3 ) and blanking ( 4 ) cylinders, and after the macroperforation process, a perforated film ( 5 ) gathered in a coil ( 6 ) is obtained.
[0011] FIGS. 2 and 3 show the variant described for 2n input coils, n output coils (the 2-1 and 4-2 combinations are represented to simplify the drawing), with which a multi-layer film, 2 layers in this case, is obtained, although as indicated above, the coil combination can be different.
[0012] FIG. 4 shows a monolayer plastic film ( 1 ) with the holes of the process described above and a multi-layer film (three in this case) formed by three sheets of film ( 1 )( 1 )( 1 ).
[0013] Finally, FIG. 5 shows the same film described above but after being subjected to the stretching process, where the holes ( 2 ) and the film ( 1 ) have suffered elongation. | 4y
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S. Provisional Patent Application No. 60/561,745, filed on Apr. 13, 2004, the contents of which are incorporated in this application by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a device and method for treating wounds. More specifically, the present invention relates to a therapeutic wound contact device.
BACKGROUND OF THE INVENTION
[0003] Wound healing is a basic reparative process of the human body. It has been known throughout time that dressing wounds with appropriate materials aids the body's natural regenerative process. Historically, such materials have been made from cotton fibers; e.g. gauze. These dressings are beneficial to the healing process because they insulate damaged tissue from external contaminants and because they remove potentially deleterious wound exudates.
[0004] Numerous studies suggest that wound healing depends on the interplay of complex mechanisms involving cell proliferation, migration and adhesion coupled with angiogenesis. Application of traditional gauze or other essentially flat materials are essentially sub-optimal with respect to these mechanisms. Wound healing studies In-vitro are carried out in cell culture vehicles that permit cellular function. It is therefore desirable in the practice of wound healing to provide the equivalent of cell culture or a bioreactor system to allow the optimal interplay of cell functions of proliferation, migration and adhesion. Additionally, it is essential to incorporate other bodily functions that encourage the supply of fibronectins, plasma proteins, oxygen, platelets, growth factors, immunochemicals and so forth.
[0005] As science and medicine have advanced, the technology incorporated into wound healing devices has improved substantially. Highly absorbent wound dressings capable of absorbing many times their weight in liquids are available. Systems that temporarily seal wounds and utilize suction to remove exudates have found widespread utilization. Dressings incorporating anti-microbial agents and biologic healing agents are common. Devices that provide a moist wound environment for improved healing have been found to be useful.
[0006] In spite of the technological gains in wound healing devices and dressings, millions of people still suffer from chronic wounds. Such chronic wounds are debilitating and can last for years, greatly diminishing the individual's quality of life. Often such wounds result in the loss of a limb. Individuals may even die from complications such as infection.
[0007] As such, there is a dire need for more effective wound healing devices and methods.
SUMMARY OF THE INVENTION
[0008] To provide for improved wound healing, the present invention is a wound contact material, a method for making the wound contact material, and a method of treatment employing the wound contact material.
[0009] According to an exemplary embodiment of the present invention, a therapeutic device for promoting the healing of a wound in a mammal is provided. The device comprises a permeable substrate or structure having a plurality of depressions formed in a surface thereof, wherein said surface having said depressions is disposed in surface contact with the wound.
[0010] According to a further exemplary embodiment of the present invention, a therapeutic device for promoting the healing of a wound in a mammal is provided. The device comprises a permeable structure having a plurality of wound surface contact elements disposed between end portions of the structure, and a plurality of voids defined by the contact elements.
[0011] According to an additional exemplary embodiment of the present invention, a therapeutic device for promoting the healing of a wound in a mammal, the device comprising a permeable structure comprising a plurality of fibers coupled to one another having a plurality of wound surface contact elements disposed between end portions of the structure and a plurality of voids defined by the contact elements is provided.
[0012] According to a yet further exemplary embodiment of the present invention, a therapeutic device for promoting the healing of a wound in a mammal, the device comprising a polyester felt having a plurality of wound surface contact elements disposed between end portions of the structure and a plurality of voids defined by the contact elements is provided.
[0013] According to an additional exemplary embodiment of the present invention, a method of manufacturing a therapeutic device for promoting the healing of a wound in a mammal comprises the steps of providing a molten substrate material providing a mold defining a plurality of depressions and a plurality of contact elements and applying the molten substrate material to the mold.
[0014] According to an even further exemplary embodiment of the present invention, a method of manufacturing a therapeutic device for promoting the healing of a wound in a mammal comprises the steps of providing a permeable structure and forming a plurality of depressions into a surface of the permeable structure.
[0015] According to another exemplary embodiment of the present invention, a method of treating a wound comprises the steps of providing a permeable structure comprising i) a plurality of wound surface contact elements disposed between end portions of the structure, and ii) a plurality of voids defined by the contact elements, and applying the permeable structure to at least one surface of the wound and applying a force to the structure to maintain the structure in intimate contact with the wound surface.
[0016] These and other aspects and objects will become apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention is best understood from the following detailed description when read in connection with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawings are the following Figures:
[0018] FIG. 1 is a perspective view of a channeled wound contact dressing according to a first exemplary embodiment of the present invention;
[0019] FIG. 2A is a perspective view of a channeled wound contact composite according to a second exemplary embodiment of the present invention;
[0020] FIG. 2B is a cross section of the channeled wound contact composite according to the second exemplary embodiment of FIG. 2A ;
[0021] FIG. 3A is a perspective view of a dimpled wound dressing according to a third exemplary embodiment of the present invention;
[0022] FIG. 3B is a top view of the dimpled wound dressing illustrated in FIG. 3A ;
[0023] FIG. 3C is a bottom view of the dimpled wound dressing illustrated in FIG. 3A ;
[0024] FIG. 3D is a cross sectional view of the dimpled wound dressing illustrated in FIG. 3A ;
[0025] FIGS. 4A, 4B , 4 C are illustrations of the dimpled wound dressing of FIG. 3A in use;
[0026] FIG. 5A is a perspective view of an irregular wound contact dressing according to a fourth exemplary embodiment of the present invention;
[0027] FIG. 5B is a cross sectional view of the irregular wound contact dressing illustrated in FIG. 5A .
DETAILED DESCRIPTION OF THE INVENTION
[0028] A wound dressing with a discontinuous contact layer surface has the advantages of promoting tissue growth with wound surface contact elements and permitting tissue growth by providing void volume for the subsequent tissue growth within the discontinuities. Desirably, the structure of the contact material is sufficiently physically rugged to resist flattening when forces required to press the material against the wound surface are applied to the material.
[0029] It is desirable for the material to retain its structure when exposed to aqueous or other bodily fluids. Many traditional dressing materials soften as they moisten so that their geometry changes. The contact layer is permeable, permitting the underlying wound to breathe and allowing for fluids to be drawn from the wound. The contact layer should not be too absorbent as this might result in a loss of structure. The layer is comprised of base materials that are resistant to change in the presence of moisture and aqueous liquids.
[0030] In the current embodiment, the extent of the voids remaining above the wound surface is preferably at least 0.1 mm when the structure is pressed against the surface of the wound. The width of the voids, as defined by contact elements adjacent the voids, is preferably greater than 0.1 mm. A more preferred width is between about 0.5 to 10 mm and a more preferred height is between about 0.2 to 5 mm.
[0031] Wound healing is recognized as a complex process. When a wound contact material as described is forced against a wound surface, a number of biological processes are believed to occur. Mechanical stress is applied to the underlying tissue. The discontinuities in the contact surface impose a force resulting in a catenary shape on the tissue. These mechanical forces encourage cellular activities as well as angiogenesis, and the discontinuities begin to fill with granular tissue. Excess fluid is conveyed away from the wound and tissue develops in a manner and pattern whereby disruption of the newly developed tissue is minimized upon removal of the contact surface.
[0032] A fibrous substrate or structure has all the flexibilities provided by the textile arts. Fibrous textiles can be formed into a structure for the invention by a number of the methods known in the art. Among these methods are knitting, weaving, embroidering, braiding, felting, spunbonding, meltblowing, and meltspinning. Each of these methods can be further adapted to produce a material whose structure matches that of the present invention. The desired structure can be imparted during production of the structure by, for example, applying molten material directly to a mold as in meltblowing. Alternatively, the structure can be formed by working a formed structure after production by, for example, heat stamping or vacuum forming. Further, fibers can be mixed with an adhesive and sprayed onto a textured surface.
[0033] The versatility of fibrous textiles also extends to their easy adaptation to composite applications. Individual fiber materials may be varied to optimize a physical parameter such as rigidity or flexibility. Individual fiber materials can also be selected for their known ability to assist in wound healing. Examples of such fiber materials are calcium alginate, and collagen. Alternatively, fibers may be treated with known wound healing agents such as hyaluronic acid or antimicrobial silver. The ratio of the fiber materials can be varied to suit the requirements of the wound. According to one desirable aspect of the invention, different fibers with various wound healing properties may be added as desired.
[0034] Other fibrous structures that are anticipated as beneficial additions include:
1. Fluid absorbing fibers 2. Non-adsorbent fibers 3. Bio-absorbable fibers 4. Wicking fibers to wick fluid away from the surface of the wound 5. Fibers with known healing effects, such as calcium alginate 6. Bio-erodable fibers for the controlled release of a curative agent 7. Conductive fibers for the delivery of an electric charge or current 8. Adherent fibers for the selective removal of undesirable tissues, substances or microorganisms 9. Non-adherent fibers for the protection of delicate tissue
[0044] An exemplary embodiment of the present invention is illustrated in FIG. 1 . As shown in FIG. 1 , channeled wound dressing 100 is comprised of a generally conformable polyester felt material 102 . An alternative polyester textile such as a knit, weave, or braid may also be suitable for most applications. Polyolefins, such as polyethylene or polypropylene, and polyamides, such as nylon, with similar physical properties are also contemplated. Creep resistance, as exhibited by polyester, is particularly desirable. Void channels 104 are cut into felt material 102 to provide a discontinuity that promotes the upward growth of new tissue. In use, the channeled wound dressing 100 is pressed against a wound in intimate contact with injured tissue. A force of 0.1 psi or more is desirably applied to the contact layer to press the contact elements against the surface of the wound. Wound contact elements 106 are thus in intimate contact with injured tissue.
[0045] FIGS. 2A and 2B illustrate a wound dressing composite 200 comprised of channeled dressing 100 and a vapor permeable adhesive backed sheet 202 . Adhesive backed vapor permeable sheets, in general, are known in the art and are believed to contribute to wound healing by maintaining a moisture level that is optimal for some wounds. In use, dressing composite 200 is placed onto the surface of the wound with its channeled dressing 100 portion in contact with the wound. Adhesive sheet 202 covers channeled dressing 100 and adheres to skin adjacent the wound. Composite 200 offers the advantages of channeled dressing 100 . Additionally, adhesive sheet 202 secures composite 200 and protects the wound from bacteria, etc. while allowing for the transmission of moisture vapor.
[0046] Another desirable embodiment of the present invention is illustrated in FIGS. 3A, 3B , 3 C, and 3 D. The substrate or structure for dimpled wound dressing 300 can be constructed from similar materials and production methods employed for channeled dressing 100 . FIG. 3A depicts a perspective view of dimpled dressing 300 with contact surface 320 on top. FIG. 3D shows a cross section of the dimpled dressing 300 which best illustrates the plurality of contact elements 322 and dimple voids 330 . Preferably, the total dimple void area comprises at least about 25% of the total dressing area. More preferably, the total dimple void area comprises at least about 50% of the total dressing area. Dimple voids 330 are partially defined by sidewalls 332 . Sidewalls 332 are partially responsible for providing rigidity necessary to resist compaction of dimple dressing 300 . Contact elements are preferably constructed to provide an arcuate contact surface. In a preferred embodiment, the radius of contact is between about 0.1 mm to 1 mm.
[0047] Dimple voids 330 can be formed in a variety of regular or irregular shapes. Preferably, dimple voids are constructed so that they are not “undercut” such that each aperture circumference is smaller than the corresponding inner void circumference. An “undercut” or reticulated void structure can cause tissue disruption when the dressing 300 is removed because any tissue that has grown into the void may be torn away when the material is removed from the wound. Additionally, undercut or reticulated void structures are more likely to result in shedding of the dressing material into the newly developing wound tissue.
[0048] In one preferred embodiment, a base material for dressing 300 is Masterflo RTM from manufactured by BBA group of Wakefield, Mass. In this exemplary embodiment, the base material has a thickness of about 1.0 mm. Dimple voids 330 are heat stamped in to the base material having a depth of about 0.75 mm and a diameter of about 2 mm.
[0049] Because the contact layer is generally replaced every few days it is important to account for the possibility of alignment of newly formed tissue with the voids of a new contact layer. Thus, according to exemplary embodiments of the present invention 1) dimple voids 330 can be arranged randomly so that they don't line up with the new tissue growth after each dressing change, 2) different contact layers with different diameter dimples may be provided, or 3) a different spacing of the dimples can be used every time the material is changed.
[0050] FIGS. 3B and 3C illustrate the corresponding top and bottom views, respectively, of dimpled dressing 300 . One variation of this embodiment is also contemplated having dimple voids 330 and/or contact elements 322 disposed on both the top and bottom of dimpled dressing 300 . A second variation on dimpled wound dressing 300 is also contemplated wherein some or all of the dimple voids 330 are replaced with holes traversing the structure's entire thickness such that the top and bottom views of the variation would appear similar to FIG. 3B .
[0051] In one exemplary embodiment, dimple voids 330 can be partially filled with therapeutic substances. For example, antiseptic substances might be placed in voids 330 for treating infected wounds. Further, biologic healing agents could be delivered in the voids to improve the rate of new tissue formation. In yet another exemplary embodiment, the layer of dressing 300 could have a different function on each side. For example, one side of dressing 300 could be optimized for the growth of new tissue, while the other side could be optimized for the delivery of anti-microbial agents, for example.
[0052] Use of dimpled dressing 300 is illustrated by FIGS. 4A, 4B , and 4 C. FIG. 4A shows a wound surface 400 . Note that wound surface 400 may represent the majority of a shallow surface wound or a small interior portion of a deep tissue wound. FIG. 4B shows application of dimpled dressing 300 to wound surface 400 and corresponding tissue growth 410 within dimple voids 330 . Finally, removal of dimpled dressing 300 leaving tissue growth 410 is illustrated in FIG. 4C . As will be addressed in detail below, it is desirable to provide an external force for keeping dressing 300 pressed against the surface of the wound.
[0053] FIGS. 5A and 5B illustrate another embodiment of the present invention; a rough irregular dressing 500 . From a perspective view, FIG. 5A depicts how irregular dressing 500 has irregular voids 510 and irregular contact elements 520 acting as “hook-like” members that are able to contact and stick to necrotic tissue when the substrate is placed in the wound. When the substrate is removed from the wound, necrotic tissue is stuck to hook like protrusions 520 and is thus removed from the wound. Removal of the substrate debrides the wound. Removal of necrotic tissue is an important part of healing wounds. The substrate of dressing 500 may be made from polyester felt or batting. In one exemplary embodiment, the felt is singed with hot air so that a percentage of the fibers melt to form a textured surface with a number of hook like elements 520 . Another suitable configuration can be the hook material such as that used with hook and loop fabric.
[0054] After adequate removal of the necrotic tissue, the wound may still be considered infected and can be treated with the substrate including antimicrobial silver, for example, which is useful in killing bacteria, while the substrate and method of use facilitate the growth of new tissue.
[0055] The phase of wound healing where new tissue is forming is generally referred to as the proliferative phase. Once the wound is adequately healed in the proliferative phase and the bacterial load is adequately reduced, a substrate without antimicrobial silver and optionally with the addition of growth enhancing materials is used to facilitate the continued proliferation of new cells and tissue.
[0056] FIG. 5B shows the random cross section of irregular dressing 500 . The roughened surface of irregular dressing 500 can be formed by passing a suitable substrate under convective heat at or about the melting point of the substrate's component material. For example, polyester materials typically melt in a range from about 250 degrees Celsius to about 290 degrees Celsius. A polyester felt material passed briefly under a convective heat source operating in this range will experience surface melting and subsequent fusing of the polyester strands at its surface. The degree of surface melting can be controlled with temperature and exposure time to yield a surface of desired roughness exhibiting irregular voids 510 and irregular contact elements. Although irregular dressing 500 is illustrated as having only one roughened surface the invention is not so limited in that both upper and lower surfaces may be similarly roughened. Such a dressing would be useful in the treatment of an undermined wound.
[0057] As described above, treatment with the present wound dressing invention comprises forcing the inventive dressing into intimate contact with the wound surface. Generally the force should be at least 0.1 psi. Various methods and systems for maintaining this intimate contact are contemplated. These methods and systems may include: applying an adhesive film over the inventive dressing and adjacent the wound surface; wrapping a bandage over the dressing and around the injured area; and securing a balloon or other inflatable bladder to the structure and inflating the bladder with air or a liquid. In one exemplary embodiment, the application of pressure to the bladder is provided intermittently. A conformable seal may be placed over the wound and contact structure, a rigid seal is then secured over the wound, contact structure imparting a force on the contact structure. A pressure is then applied between the rigid seal and the flexible seal forcing the contact structure against the wound surface. The intimate contact may be augmented by sealing the wound area with a conformable cover and applying suction. When suction is used, dimpled wound dressing 300 is particularly well-adapted for this application. In general the range of suction levels is between 0.25 PSI and 5 psi. The suction use can be further improved by applying a wound packing material to the back of the dressing. One such suitable wound packing material is described in U.S. Provisional Patent Application No. 60/554,158, filed on Mar. 18, 2004.
[0058] Case Study 1
[0059] Patient A is a 70 year old male with a Stage IV decubitus ulcer on the right hip with significant undermining. The contact structure of the present invention was applied to the wound and an adhesive film was placed over the wound and the contact structure. A suction of 1.1 psi was applied beneath the adhesive film to impart a force upon the contact structure. The suction was maintained generally continuously. The contact material was replaced every two to four days. After use of the device for 30 days the undermined portion of the wound had virtually healed and the area of the wound opening had decreased from 66 square cm to 45 square cm. A split thickness skin graft was applied to the wound.
[0060] Case Study 2
[0061] Patient B is a 50 year old male with a facture of the right ankle with exposed bone. A plate was used to reduce the fracture and a rectus abdominus free flap was performed to cover the exposed bone and hardware. The flap only partially survived resulting in an open wound with exposed bone and hardware. The contact structure of the present invention was applied to the wound and an adhesive film was placed over the wound and the contact structure. A force was applied to the contact structure by the application of an ace bandage wrapped around the ankle or by the application of suction. The suction force was generally applied for about half of the day and the force of the bandage wrap was maintained for the remainder of the day. For a number of days, the bandage wrap was solely used to impart the force. When the force was imparted by suction a suction of between 1 and 2 psi was used. In less than 2 weeks new tissue had grown over the exposed hardware. In a period of 7 weeks the wound area was reduced from to 50 square cm to 28 square cm.
[0062] While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention. | 4y
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TECHNICAL FIELD
The invention relates generally to a router and, more particularly, to router having a wireless switching fabric.
BACKGROUND
Turning to FIGS. 1 and 2 , a diagram of a example of a conventional router 100 can be seen. This router 100 is generally housed within a chassis that includes a wired switching fabric 104 (which is generally comprised of “long reach” serializer/deserializer (SerDes) links) which is controlled by a controller 102 . These “long reach” SerDes links can be up to several feet in length, are complex in construction, and consume a large amount of power. Coupled (through slots 106 - 1 to 106 -N) to the this switching fabric 104 (which is part of “backplane” of the router 100 ) are line card 108 - 1 to 108 -N. These line cards 108 - 1 to 108 - 2 (labeled 108 in FIG. 2 for the sake of simplicity) generally include a fabric interface 110 that communicates with the fabric 104 through slots 106 - 1 to 106 -N (labeled 106 in FIG. 2 for the sake of simplicity) and ports 112 - 1 to 112 -R that communicate with the interface 110 over “short reach” SerDes links. The ports 112 - 1 to 112 -R generally include Ethernet connections (i.e., through RJ45 connectors).
This conventional arrangement has numerous drawbacks. Principally, the backplane (which includes the switching fabric 104 ) is complex, expensive, and consumes a large amount of power. Thus, there is a need to for improved router backplanes.
Some examples of conventional systems are: U.S. Pat. No. 5,754,948; U.S. Pat. No. 6,967,347; U.S. Pat. No. 7,330,702; U.S. Pat. No. 7,373,107; U.S. Pat. No. 7,379,713; U.S. Pat. No. 7,768,457; U.S. Patent Pre-Grant Publ. No. 2009/0009408; and U.S. Patent Pre-Grant Publ. No. 2009/0028177.
SUMMARY
A preferred embodiment of the present invention, accordingly, provides an apparatus. The apparatus comprises a printed circuit board (PCB); a plurality of ports that are each secured to the PCB; a forwarding circuit that is secured to PCB, wherein the forwarding circuit is in communication with each of the plurality of ports; and a plurality of input/output (IO) circuits, wherein each IO circuit is secured to the PCB and is in communication with the forwarding circuit, and wherein each IO circuit is configured to provide a millimeter wave link in a direction extending from the PCB, and wherein the plurality of IO circuits are arranged on the PCB and spaced apart from one another so as to isolate each millimeter wave link.
In accordance with an embodiment of the present invention, the forwarding circuit is in communication with the plurality of ports by a first set of serializer/deserializer (SerDes) links, and wherein the forwarding circuit is in communication with the plurality of IO circuits by a second set of SerDes links.
In accordance with an embodiment of the present invention, the PCB further comprises a top surface and a bottom surface, and wherein the millimeter wave link for each IO circuit further comprises: a first transmit link that is configured to transmit data to a receiver facing the top surface of the PCB; a first receive link that is configured to receive data from a transmitter facing the top surface of the PCB; a second transmit link is configured to transmit data to a receiver facing the bottom surface of the PCB; and a second receive link that is configured to receive data from a transmitter facing the bottom surface of the PCB.
In accordance with an embodiment of the present invention, each IO circuit further comprises a transceiver that is secured to the top surface of the PCB, that is communication with the forwarding circuit, and that provides the first transmit link and the first receive link.
In accordance with an embodiment of the present invention, the PCB further comprises a plurality of radio frequency (RF) windows, wherein each RF window is substantially aligned with the transceiver from at least one of the IO circuits so that the transceiver provides the second transmit link and the second receive link.
In accordance with an embodiment of the present invention, each IO circuit further comprises a relay circuit that is secured to the bottom surface of the PCB, that is in communication with the forwarding circuit, and that provides the second transmit link and the second receive link.
In accordance with an embodiment of the present invention, the transceiver from each IO circuit further comprises a phased array.
In accordance with an embodiment of the present invention, an apparatus is provided. The apparatus comprises a chassis having a first slot and a second slot; a first active card that is secured to the first slot, wherein the first active card includes: a first PCB; a first set of ports that are each secured to the first PCB; a first forwarding circuit that is secured to first PCB, wherein the first forwarding circuit is in communication with each port from the first set of ports; and a first set of IO circuits, wherein each IO circuit from the first set is secured to the first PCB and is in communication with the first forwarding circuit, and wherein the first set of IO circuits are arranged on the first PCB and spaced apart from one another by at least a first distance; and a second active card that is secured to the second slot and that is separated from the first active card by a second distance, wherein the second active card includes: a second PCB; a second set of ports that are each secured to the second PCB; a second forwarding circuit that is secured to second PCB, wherein the second forwarding circuit is in communication with each port from the second set of ports; and a second set of IO circuits, wherein each IO circuit from the second set is secured to the second PCB and is in communication with the second forwarding circuit, and wherein the second set of IO circuits are arranged on the second PCB and spaced apart from one another by at least the first distance, and wherein each IO circuit from the first set is substantially aligned with an IO circuit from the second set so as to provide a millimeter wave link between each pair of aligned IO circuits, and wherein the first distance and the second distance are sufficiently large to isolate the millimeter wave link between each pair of IO circuits.
In accordance with an embodiment of the present invention, the chassis further comprises: a rack that includes the first and second slots; and a routing processor that is in communication with the first and second forwarding circuits.
In accordance with an embodiment of the present invention, the first forwarding circuit is in communication with the first set of ports by a first set of SerDes links, and wherein the first forwarding circuit is in communication with the first set of IO circuits by a second set of SerDes links, and wherein the second forwarding circuit is in communication with the second set of ports by a third set of SerDes links, and wherein the second forwarding circuit is in communication with the second set of IO circuits by a fourth set of SerDes links.
In accordance with an embodiment of the present invention, the each of the first and second PCBs further comprises a top surface and a bottom surface, and wherein the millimeter wave link for each pair of aligned IO circuits further comprises a transmit link and a receive link.
In accordance with an embodiment of the present invention, each IO circuit from the first and second sets further comprises a transceiver that is secured to the top surface of its PCB and that is communication with its forwarding circuit.
In accordance with an embodiment of the present invention, the bottom surface of the first PCB faces the top surface of the second PCB, and wherein the first PCB further comprises a plurality of RF windows, and wherein each RF window is substantially aligned with the transceiver from at least one of the IO circuits from the first set.
In accordance with an embodiment of the present invention, each IO circuit from the first set further comprises a relay circuit that is secured to the bottom surface of the first PCB, which is in communication with the first forwarding circuit.
In accordance with an embodiment of the present invention, an apparatus is provided. The apparatus comprises a chassis having a rack with a plurality of slots; a plurality of line cards that are arranged in a sequence, wherein each line card is secured to at least one of the slots and separated by a first distance, wherein each line card includes: a PCB; and a set of IO circuits, wherein each IO circuit from the set is secured to the PCB, and wherein each IO circuit set is substantially aligned with a corresponding IO circuit from an adjacent line card so as to provide a millimeter wave link between each aligned pair of IO circuits, and wherein the set of IO circuits are arranged on the PCB and spaced apart from one another by at least a first distance, and wherein the first distance and the second distance are sufficiently large to isolate the millimeter wave link between each pair of IO circuits.
In accordance with an embodiment of the present invention, at least one of the line cards further comprises an active card having a forwarding circuit that is secured to its PCB and that is communication with its ports and its IO circuits.
In accordance with an embodiment of the present invention, at least one of the line cards is a relay card.
In accordance with an embodiment of the present invention, the chassis further comprise a plurality of waveguides, wherein each waveguide is substantially aligned with at least one IO circuit from each of the first and last line cards.
In accordance with an embodiment of the present invention, an apparatus is provided. The apparatus comprises a printed circuit board (PCB) having: a top surface; a bottom surface; and a plurality of serializer/deserializer (SerDes) lanes; an input/output (IO) circuit having a transceiver that is secured to the top surface of the PCB, wherein transceiver includes: a SerDes circuit that is coupled to the plurality of SerDes lanes; an intermediate circuit that is coupled to the SerDes circuit; a transmitter that is coupled to the intermediate circuit; a receiver that is coupled to the intermediate circuit; and an antenna that is coupled to the transmitter and the receiver, wherein the transmitter and the antenna are configured to provide a millimeter wave transmit link at a first frequency in a direction that extends from the top surface of the PCB, and wherein the receiver and the antenna are configured to provide a millimeter receive link at a second frequency in the direction that extends from the top surface of the PCB.
In accordance with an embodiment of the present invention, the millimeter wave transmit and receive links further comprise a first millimeter wave transmit link and a first millimeter wave receive link, and wherein the PCB further comprises a radio frequency (RF) window that is substantially aligned with the transceiver, wherein the transmitter and antenna are configured to provide a second millimeter wave transmit link in a direction that extends from the bottom surface of the PCB, and wherein the receiver and antenna are configured to provide a second millimeter wave receive link in the direction that extends the bottom surface of the PCB.
In accordance with an embodiment of the present invention, the millimeter wave transmit and receive links further comprise a first millimeter wave transmit link and a first millimeter wave receive link, and wherein the IO circuit further comprises a relay circuit that is secured to the bottom surface of the PCB and that is substantially aligned with the transceiver, wherein the relay circuit is configured to provide a second millimeter wave receive link in the direction that extends from the bottom surface of the PCB.
In accordance with an embodiment of the present invention, the SerDes circuit further comprises a serializer and a deserializer.
In accordance with an embodiment of the present invention, the intermediate circuit further comprises: a lane aggregation circuit that is coupled between the serializer and the transmitter; and a lane de-aggregation circuit that is coupled between the receiver and the deserializer and that is coupled to the lane aggregation circuit.
In accordance with an embodiment of the present invention, the SerDes circuit, the intermediate circuit, the transmitter, the receiver, and the antenna further comprise a first SerDes circuit, a first intermediate circuit, a first transmitter, a first receiver, and a first antenna, and wherein the relay circuit further comprises: a second SerDes circuit; a second intermediate circuit that is coupled to the second SerDes circuit; a second transmitter that is coupled to the second intermediate circuit; a second receiver that is coupled to the second intermediate circuit; and a second antenna that is coupled to the second transmitter and the second receiver.
In accordance with an embodiment of the present invention, the serializer and the deserializer further comprise a first serializer and a first deserializer, and wherein the second SerDes circuit further comprises a second serializer and a second deserializer.
In accordance with an embodiment of the present invention, the intermediate circuit further comprises: a multiplexer that is coupled between the second serializer and the second transmitter; and a demultiplexer that is coupled between the second receiver and the second deserializer.
In accordance with an embodiment of the present invention, an apparatus is provided. The apparatus comprises a PCB having: a top surface; a bottom surface; and a plurality of SerDes lanes; an IO circuit having: an integrated circuit (IC) having: a SerDes circuit; an intermediate circuit that is coupled to the SerDes circuit; a transmitter that is coupled to the intermediate circuit; and a receiver that is coupled to the intermediate circuit; an antenna package that is secured to the top surface of the PCB, wherein the IC is secured to the antenna package and is communication with the plurality of SerDes lanes through the antenna package, and wherein the transmitter and the antenna package are configured to provide a millimeter wave transmit link at a first frequency in a direction that extends from the top surface of the PCB, and wherein the receiver and the antenna package are configured to provide a millimeter receive link at a second frequency in the direction that extends from the top surface of the PCB.
In accordance with an embodiment of the present invention, the antenna package further comprises a plurality of antennas arranged to operate as a phased array.
In accordance with an embodiment of the present invention, the antenna package further comprises a high impedance surface (HIS) that substantially surrounds the plurality of antennas.
In accordance with an embodiment of the present invention, the IC and antenna package further comprise a first IC and a first antenna package, and wherein the SerDes circuit, the intermediate circuit, the transmitter, and the receiver further comprise a first SerDes circuit, a first intermediate circuit, a first transmitter, and a first receiver, and wherein the millimeter wave transmit and receive links further comprise first millimeter wave transmit and receive links, and wherein the IO circuit further comprises: a second IC having: a SerDes circuit; an intermediate circuit that is coupled to the SerDes circuit; a transmitter that is coupled to the intermediate circuit; and a receiver that is coupled to the intermediate circuit; and a second antenna package that is secured to the bottom surface of the PCB, and wherein the second transmitter and the second antenna package are configured to provide a second millimeter wave transmit link at the second frequency in a direction that extends from the bottom surface of the PCB, and wherein the receiver and the antenna package are configured to provide a second millimeter receive link at the first frequency in the direction that extends from the bottom surface of the PCB.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a diagram of an example of a conventional router;
FIG. 2 is a diagram of a line card for the router of FIG. 1 ;
FIG. 3 is a diagram of an example of a router in accordance with an embodiment of the present invention;
FIG. 4 is a diagram of an example of an active card for the router of the FIG. 3 ;
FIG. 5 is a diagram of an example of a relay card for the router of FIG. 3 ;
FIGS. 6 and 7 are cross-sectional view of the active card of FIG. 4 along section line I-I;
FIG. 8 is a diagram of an example of the relay circuit of FIG. 6 ;
FIG. 9 is a diagram of an example of the transceiver of FIG. 6 ;
FIGS. 10 and 11 are radiation patterns for a single antenna for the relay circuit and transceiver of FIGS. 8 and 9 ;
FIG. 12 is a cross-sectional view of the active card of FIG. 4 along section line I-I;
FIG. 13 is a plan view of the antenna package of FIG. 12 ;
FIGS. 14-19 are radiation patterns for phased arrays for the IO circuit of FIG. 12 ; and
FIG. 20 is a diagram depicting system redundancy.
DETAILED DESCRIPTION
Refer now to the drawings wherein depicted elements are, for the sake of clarity, not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views.
Turning to FIG. 3 , an example of a router 200 in accordance with an embodiment of the present invention can be seen. As shown, communication between line cards 202 - 1 to 202 -N is provided through wireless millimeter wave links (i.e., between 100 GHz and 10 THz) instead of through “long reach” SerDes links. Each card 202 - 1 to 202 -N is secured within a rack 206 (which is part of the router chassis 208 ). The rack 206 is able to power each of the line cards 202 - 1 to 202 -N and to provide controls from a processor (i.e., controller 102 of FIG. 1 ). Each card 102 - 1 to 102 -N is able to provide multiple transmit and receive links to its adjacent line cards. Additionally, a waveguide (or many waveguides) can be included within chassis 208 to allow the first line card 202 - 1 to the last line card 202 -N.
In order to be able to create these wireless millimeter wave links, the line cards 202 - 1 to 202 -N should be arranged in a manner in which the links do not interfere with one another, which can be seen in FIGS. 4 and 5 . As shown, two different types of line cards 202 - 1 and 202 -N can be employed: active cards 201 and relay cards 203 . Active cards 201 are generally include ports 112 - 1 to 112 -R, whereas relay cards 203 . This allows for the assembly of a lower cost router 200 , where some active cards 201 are replaced with relay cards 203 , allowing the millimeter wave links are present so as to generally maintain the same functionality. Active cards 201 are generally comprised of IO circuits 304 - 1 to 304 - 6 (more may be included) that are secured to the printed circuit board (PCB) 306 and spaced apart from one another by a distance D 1 such that the transmit and receive links for adjacent IO circuits (i.e., IO circuit 304 - 1 and 304 - 2 ) do not interfere with one another. Each of these IO circuits 304 - 1 to 304 - 6 is coupled to a forwarding circuit 302 over “short reach” SerDes links (which can include multiple SerDes lanes). The forwarding circuit 302 is also coupled to ports 112 - 1 to 112 -R. The relay card 203 , on the other hand, has relay circuits 402 - 1 to 402 - 6 that are secured to PCB 406 and arranged in a similar manner to IO circuits 304 - 1 to 304 - 6 . These relay circuits 402 - 1 to 402 - 6 are also coupled to a relay controller 404 over “short reach” SerDes links.
Turning to FIG. 6 , an example arrangements for IO circuit 304 (labeled 304 -A for FIG. 6 ) can be seen. As shown, IO circuit 304 -A id generally comprised of a transceiver 502 secured to the top surface of the PCB 306 -A and a relay circuit 402 -A secured to the bottom surface of PCB 306 -A. Each of the transceiver 502 and relay circuit 402 -A is coupled to the forwarding circuit 302 over “short reach” SerDes links and each has a transmit link and a receive link that extend from the top and bottom surfaces of the PCB 306 -A, respectively. The transmit and receive links are also usually at different frequencies to avoid interference. For example, the transmit link and receive link for transceiver 502 and be 160 GHz and 120 GHz, respectively, and the transmit and receive links for relay circuit 402 -A can be 120 GHz and 160 GHz, respectively. Additionally, for relay card 203 , relay circuits (i.e., 404 - 1 ) are secured to the top surface and bottom surface of PCB 406 in a similar arrangement.
Another approach (as shown in FIG. 7 ) is to employ transceiver 504 in IO circuit 304 -B. For this example, transceiver 504 provides transmit and receive links that extend from both the top and bottom surfaces of the PCB 306 -B. For the transmit and receive links extending from the top surface of the PCB 306 -B, transceiver 504 function in a similar manner to transceiver 502 , but, because PCBs (i.e., PCB 306 -B) often include layers that are reflective or opaque to millimeter wave radiation, the PCB 306 -B is configured to be roughly transparent. This is accomplished by having a radio frequency (RF) window 506 positioned below or aligned with transceiver 504 . In this RF window 506 , openings are formed in layers that are opaque or reflective to millimeter wave radiation so as to allow the transceiver to form transmit and receive links that extend from the bottom surface of the PCB 306 -B.
Turning to FIG. 8 , a diagram of an example of a relay circuit 402 can be seen. In this example, the relay circuit 402 is generally comprised of a SerDes circuit (which generally includes a serializer 602 and deserializer 608 ), an intermediate circuit (which generally includes multiplexer 604 and demultiplexer 610 ), a transmitter 606 , a receiver 612 , and an antenna 614 . Typically, the SerDes circuit is coupled to SerDes lanes so as to communicate (i.e., provide and receive data packets) with a forwarding circuit 302 or relay controller 404 . The multiplexer 604 and demultiplexer 610 are also controlled by the forwarding circuit 302 or relay controller 404 so as to control the data flow from the receiver 612 and to transmitter 606 .
In FIG. 9 , a diagram of an example of the transceiver 502 or 504 can be seen. This transceiver 502 or 504 is generally comprised of a SerDes circuit (which generally includes a serializer 602 and deserializer 608 ), an intermediate circuit (which generally includes lane aggregation circuit 702 and lane de-aggregation circuit 704 ), a transmitter 606 , a receiver 612 , and an antenna 614 . The lane aggregation circuit 702 and lane de-aggregation circuit 704 are typically coupled to the transmitter 606 and receiver 612 via a high speed serial interface and coupled to the SerDes circuit through a low speed parallel interface. This allows data to be communicated to and from the forwarding circuit 302 over SerDes lanes.
One important characteristic (which was mentioned above) is the spacing of the IO circuits 304 - 1 to 304 - 6 and/or relay circuits 402 - 1 to 402 - 6 . This spacing is typically premised on the shape of the beam formed by antenna (i.e., antenna 614 ). Turning to FIGS. 10 and 11 , examples of the radiation patterns for single antennas can be seen. As shown, these beams are fairly wide. This means that the distance D 1 may be on the order of 2.5-inches or more, but, to achieve narrower spacing, a phased array can be employed.
As shown in the example of FIG. 12 , phased array transceivers 702 and 704 can be employed in IO circuit 304 -C. These transceiver 702 and 704 are each generally comprised of a integrated circuit 706 and antenna package 708 . For example, IC 706 can be a terahertz or millimeter wave phased array system that includes multiple transceiver circuits. An example of such an IC can be seen in co-pending U.S. patent application Ser. No. 12/878,484, which is entitled “Terahertz Phased Array System,” filed on Sep. 9, 2010, and is hereby incorporated by reference for all purposes. This IC 706 is then secured to the antenna package 708 to allow each transceiver (for example) to communicate with a transceiver antenna included on the antenna package 708 . The antenna package 708 is then secured to the PCB 306 -A with solder balls 710 to allow the IC 706 to communicate with the forwarding circuit 302 through the antenna package 708 . Alternatively, IC 706 and antenna package 708 can form relay circuit 402 so that other, alternative configurations (such as relay card 203 ) can be formed.
Turning to FIG. 13 , an example of the antenna package 708 can be seen in greater detail. As shown, the antenna package 708 includes a phased array 804 that is substantially surrounded by a high impedance surface (HIS) 802 . An example of such an HIS can be seen in U.S. patent application Ser. No. 13/116,885, which is entitled “High Impedance Surface,” was filed on May 26, 2011, and is hereby incorporated by reference for all purposes. Also, as shown, the phased array 804 includes transceiver antennas 806 - 1 to 806 - 4 , but any number of antennas is possible that are arranged into the four quadrants or regions. This phased array 204 can then be used to steer the beam of radiation.
Examples of the radiation patterns formed the phased array 804 can be seen in FIGS. 14-19 . Specifically, the radiation patterns of FIGS. 14-19 are for phased array 804 being 2×2, 3×3, and 4×4 arrays with 4 and 16 quadrature amplitude modulation (QAM). As can be seen the lobes are significantly narrower. For the example 2×2 phased array using 4-QAM of FIG. 14 , the main lobe is about 104°, and, with an antenna area of 4 mm 2 , this would mean that the distance D 1 is about 2.55-inches. For the example 2×2 phased array using 16-QAM of FIG. 15 , the main lobe is about 124°, and, with an antenna area of 4 mm 2 , this would mean that the distance D 1 is about 3.75-inches. For the example 3×3 phased array using 4-QAM of FIG. 16 , the main lobe is about 66°, and, with an antenna area of 9 mm 2 , this would mean that the distance D 1 is about 1.3-inches. For the example 3×3 phased array using 16-QAM of FIG. 17 , the main lobe is about 76°, and, with an antenna area of 9 mm 2 , this would mean that the distance D 1 is about 1.55-inches. For the example 4×4 phased array using 4-QAM of FIG. 18 , the main lobe is about 46°, and, with an antenna area of 16 mm 2 , this would mean that the distance D 1 is about 0.85-inches. For the example 4×4 phased array using 16-QAM of FIG. 19 , the main lobe is about 54°, and, with an antenna area of 16 mm 2 , this would mean that the distance D 1 is about 1.0-inches.
By employing phased arrays, not only can the spacing be narrowed, but redundancy can be built in as well. Because of the configuration of router 200 , some redundancy is already present. For example, if line card 202 - 3 were to fail and the millimeter wave transmit and receive links with line cards 202 - 2 and 202 - 4 to line card 202 - 3 are unavailable, routing can be performed through the waveguide 204 . Assuming this failure of line card 202 - 3 and a packet is intended to be routed from line card 202 - 1 to 202 - 4 , the packet could travel through the waveguide 204 to line card 202 -N and relayed up to line card 202 - 4 . However, with phased arrays, beam steering can be used as well to redirect links.
Turning to FIG. 20 , a example of redundancy can be seen. In this example, IO circuit 304 - a of line card 202 - a has failed, so the transmit and receive links between IO circuit 304 - c and 304 - a are not functioning. Because IO circuit 304 - c includes a phased array, it can perform beam steering and can use reflections to the nearest IO circuit (which would be IO circuit 304 - b ) using the shortest reflected path. In this example, the line cards 202 - a and 202 - b are separated from one another by distance D 2 (which can, for example, be about 2-inches) and IO circuit pairs 304 - a / 304 - c and 304 - b / 304 - d are separated from one another by distance D 1 (which can, for example, be about 3.75 inches). The IO circuit 304 - c can steer the beam for its transmit link by an angle θ (about 32°, for example) from the norm, meaning that the beam would reflect off of line card 202 - a at distance D 3 (which, for example, can be 1.25-inches) and reflect off of line card 202 - b at distance 2*D 3 (which can, for example, be 2.5-inches) so as to be received by IO circuit 304 - b . An encoding scheme (such as orthogonal frequency-division multiplexing or ODFM) can the be used so that IO circuit 304 - b can communicate with both 304 - c and 304 - d.
Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | 4y
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This is a continuation of application Ser. No. 361,135 filed May 17, 1973, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to a composition of superactive fluorocarbonated products useful as bases or starting materials for the manufacture of fire extinguishing mixtures and having particular utility in combating hydrocarbon fires.
2. Description of the Prior Art
The efficacy of the compositions of the present invention as fire extinguishing agents depends essentially on their film-forming properties and on the solidity or strength of the films produced. It is moreover additionally advantageous that these solutions have good foaming properties, since the most commonly employed method of combating fire comprises projecting the solution at the base of the fire in the form of a foam. Unfortunately, the foam itself does not resist the heat radiated from adjacent localities or parts of the fire as well as would be desired, and the action of the foam should be supplemented by the formation of a film which is impermeable to the vapors [products of combustion] and resulting from spreading of the solution. The film actually consists of a colloidal fluorinated membrane which adheres to the surface of the hydrocarbon and which supports a liquid film of the aqueous surface-active solution, according to the principle which is well known under the name of "light water" and which is described in U.S. Pat. No. 3,258,423.
The film has several functions, first it isolates the combustible material from the oxygen of the atmosphere, further since it releases water vapor directly at the base of the flames it thereby retards combustion, and finally it functions as a thermal screen, that is as an insulator, between the combustible material and the vapors that are already in the process of burning.
It is known that a liquid, B, can spread on a liquid, A, only if the work of adhesion, T AB , corresponding to the formation of the interface AB, is greater than the work of cohesion of the liquid B, T cohB , which work of cohesion is equal to twice the surface tension, X B . If T AB is replaced by the value for it in the Dupre equation and if the spreading coefficient, S, denotes the quantity T AB - T cohB , then the condition for spreading can be written as
S = (γ.sub.A +γ.sub.B - γ.sub.AB) - 2γ.sub.B >0,
wherein
γ AB is the interfacial tension between the liquids A and B, i.e.
S = γ.sub.A - (γ.sub.B +γ .sub.AB) > 0
these quantities are directly determinable from experimentation and conequently it is possible to predict the behavior of the two immiscible liquids in presence of each other.
The above formulae show that the spreading properties of the aqueous surface-active solutions will be inversely related to their surface tension and to their interfacial tension with respect to the hydrocarbon. The interfacial tension is determined by the molecular structure of the compounds and the polar interactions which can result therefrom, and has only a small effect on aliphatic hydrocarbons.
The surface tension of an aqueous solution can be reduced by increasing the concentration of the surface-active agent, however, there is a limit to achieving a reduction in this manner, due to the critical micellar concentration beyond which it is not possible to obtain a decreased value.
In practice, the majority of the fluorinated surface-active compounds which are described in the literature, and particularly those cited in French patents Nos. 1,405,794 and 2,035,584, and in U.S. Pat. Nos. 2,764,602 and 3,258,423, do not permit the formation of durable films on hydrocarbons whose surface tension is lower than 22 to 23 dynes per centimeter, for example, high octane gasoline whose surface tension is 22.4 dynes/cm.
SUMMARY OF THE INVENTION
The fire extinguishing material of this invention, which are to be utilized in aqueous solution, may be made up exclusively of mixtures of the disclosed fluorinated materials or of mixtures of these materials and of proteins, optionally supplemented with other ingredients. These proteins or additives are known and described in 3M U.S. Pat. No. 3,258,423, and are substances such as, for example, keratin, albumin, globulin, hemoglobulin and cereal flours, modified by hydrolysis and stabilized with salts of polysolvent metals such as ferrous sulphate. These additives may also be dried powders, such as for example potassium bicarbonate. By virtue of their remarkable tensio-active or surface-active film-forming properties, the solutions obtained from mixtures of the disclosed fluorinated material may also find use in particular hydrocarbons as evaporation retarding agents for volatile liquid organic compounds. Protection of the free surfaces of a hydrocarbon mass by an impermeable fluorinated film substantially increases the safety of all installations where large quantities of flammable liquid organic materials are stored and handled.
Such materials are obtained by taking advantage of the conjoined actions of:
1. a surface-active fluorocarbonated ampholyte of the formula: ##EQU4##
2. anion-ionic surface-activated fluorcarbonated material of the formula:
C.sub.n F.sub.2n.sub.+1 -- (CH.sub.2).sub.a -- CO -- O -- (CH.sub.2 -- CH.sub.2 -- O).sub.m P.sub.4 (II)
and,
3. a salt of a polyfluorinated acid and an amine including at least one hydrophilic group ##EQU5## or one quaternized tertiary group of the formula:
C.sub.n F.sub.2n.sub.+1 -- (CH.sub.2).sub.a -- XO.sup.-, N.sup.+H.sub.2 R.sub.1 -- (CH.sub.2).sub.p N.sup.+(R.sub.2 R.sub.3) -- (CH.sub.2).sub.q --COO.sup.- (IV)
the surface active fluorcarbonated ampholyte compounds of Formula I which may be used as constituents of the compositions of this invention are the products described in French Patents Nos. 2,088,699 of Dec. 13, 1971, and 2,127,287 of Sept. 18, 1972. They correspond to Formula I ##EQU6## which contains a straight or branched perfluorinated chain, and in which n is an integer between 1 and 20; a is a number between 2 and 10, R 1 is a hydrogen atom or an alkyl radical containing from 1 to 6 carbon atoms, R 2 and R 3 are alkyl radicals containing from 1 to 3 carbon atoms, at least one of these radicals being a methyl radical, and in which p and q are integers between 0 and 10.
The non-ionic surface-active fluorcarbonated compounds are products of the general formula:
C.sub.n F.sub.2n.sub.+1 -- (CH.sub.2).sub.a -- CO -- O -- (CH.sub.2 -- CH.sub.2 -- O).sub.m R.sub.4 (II)
wherein n and a have the same meanings as set forth above, m is an integer between 1 and 20, and R 4 is an alkyl radical containing from 1 to 6 carbon atoms.
These compounds are prepared by conventional esterification of the acids C n F 2n +1 -- (CH 2 ) a COOH by means of polyethoxylated ω-alkylated alcohols of the general formula
HO -- (CH.sub.2 -- CH.sub.2 -- O).sub.m R.sub.4
the salts of polyfluorinated acids and of the quaternized amines of the Formula IV are obtained by the action of a lactone ##EQU7## on salts of polyfluorinated acids of the formula
C.sub.n F.sub.2n.sub.+1 -- (CH.sub.2).sub.a -- XOH
and diamines of the formula ##EQU8## in which C n F 2n +1 ; a n, a, p, q, R 1 , R 2 , and R 3 correspond to the definitions given above.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The applicants have found that solutions of mixtures of two fluorinated surface-active agents, one the ampholyte of Formula I and the other the non-ionic agent of Formula II, possess a surface tension which varies as a function of the proportions of the two constituents and which can in certain cases and for a given composition possess minimum values lower by several dynes per centimeter than the value possessed by solutions of the pure constituents at the same total concentration.
Table I shows by way of example the variation of the surface tension in solutions prepared from 0.5% solutions of the ampholyte surface-active agent
C.sub.8 F.sub.17 C.sub.2 H.sub.4 -- CO -- NH -- (CH.sub.2).sub.3 N.sup.+ (CH.sub.3).sub.2 CH.sub.2 -- CH.sub.2 -- COO.sup.- (I.sub.1)
and of the non-ionic surface-active compound
C.sub.6 F.sub.13 -- C.sub.2 H.sub.4 -- COO -- (CH.sub.2 -- CH.sub.2 -- O).sub.7 -- CH.sub.3 (II.sub.1)
table i__________________________________________________________________________volumes of aqueous 0.50% solutions in cm.sup.3 Surface tension of the mixtures in dynes/cmAmpholyte fluorinated Non-ionic fluori- at 20.5°Ccompound nated compoundI.sub.1 II.sub.1__________________________________________________________________________100 cm.sup.3 0 cm.sup.3 20.975 cm.sup.3 25 cm.sup.3 17.150 cm.sup.3 50 cm.sup.3 15.725 cm.sup.3 75 cm.sup.3 16.4 0 cm.sup.3 100 cm.sup.3 17.1__________________________________________________________________________
The solutions obtained starting with the two types of compounds described produce films which spread very rapidly but which are fragile and have rather low foam-forming properties.
Drainage or run-off of the aqueous solutions must be sufficiently rapid to compensate for the destruction of the film by the fire and at the same time be sufficiently slow and progressive to extend throughout the extinction process and to avoid the formation of large continuous sheets of dense liquid whose weight would overcome the interfacial tensions.
The applicants have determined that the addition of a salt of a polyfluorinated acid and a diamine: ##EQU9## substantially increases the foaming properties of the previously described binary i.e. two element, combination. For example, Table 2 shows that the foaming power increases continuously in solutions of 0.5% by weight of fluorinated products having increasing proportions of the diamine salts
C.sub.6 F.sub.13 C.sub.2 H.sub.4 COOH, NH.sub.2 -- (CH.sub.2).sub.3 -- N(CH.sub.3).sub.2
TABLE 2__________________________________________________________________________Ampholyte fluoro- Non-ionic fluori- Salt of fluori- Foamingnated compound I.sub.1 nated compound II.sub.1 nated acid and power of diamineVolume of 0.5% Volume of 0.5% Volume of 0.5%solution in cm.sup.3 solution in cm.sup.3 solution in cm.sup.3 in cm.sup.3__________________________________________________________________________590 410 0 470540 360 100 420640 160 200 520480 120 400 620__________________________________________________________________________
The foaming power, determined according to the ISO TC 91 - 182 F standard, corresponds to the volume of foam developed when, under specified conditions, 500cc of an aqueous solution of the surface-active mixture are poured with the aid of a calibrated funnel into 100cc of the same solution placed at the bottom of a calibrated two litter vessel. The quality of the foam obtained is defined by the speed at which it drains off which is determined by the time necessary to collect at the bottom of the graduated vessel a volume of solution equal to one-quarter the volume of foam initially introduced. For the results to be comparable, the foam must be brought to a constant level or degree of expansion corresponding to an 8 to 10 ratio of the volume of foam to the volume of solution used for its preparation.
The efficacy of a fire-extinguishing solution is also dependent on the speed of spreading of the film and on its cohesion. A good film is one which spreads at a speed of 30 to 40 square centimeters per second on cyclohexane and which resists mechanical disturbance such as bubbles of vapor emanating from the subjacent liquid or turbulent motion without being permanently torn.
The speed of spreading of the film is an important characteristic and is evaluated in the following manner: A crystallizer of 145mm diameter is half filled with cyclohexane. Five (5) drops of a 0.5% solution of the mixture of fluorinated surface-active materials are deposited in the center of the cyclohexane. The difference in light reflecting power makes it possible to follow the spread of the fluorinated film and thus to measure the time necessary for coverage of the entire surface of the cyclohexane.
Two methods have already been proposed to improve the spreading speeds of film forming fluorinated surface-active compounds. According to French patent No. 2,009,827 a water soluble hydrocarbon surface-active compound is added to the fluorinated surface active material. According to British patent BP 1,230,980, a hydrocarbon surface-active agent, preferably chosen from among the quaternary ammonium salts is added instead. The applicants have found that the salts of polyfluorinated acids and diamines hereinabove described also act to increase the film spreading speed as is shown in Table 3 for tests carried out with mixtures prepared from the products used previously in the tests for which results were shown in Tables 1 and 2.
TABLE 3__________________________________________________________________________Volumes of aqueous 0.5% solutions in cm.sup.3Ampholyte fluori- Non-ionic fluori- Salt of fluori- Spreadingnated compound I.sub.1 nated compound II.sub.1 nated acid and speed in of diamine seconds__________________________________________________________________________30 20 0 1328.8 19.2 2 1828.2 18.8 3 827.6 18.4 4 1027 18 5 724 16 10 618 12 20 412 8 30 46 4 40 30 0 50 2__________________________________________________________________________
When the experiment is carried out with one of these three component mixtures, it is observed after an initial spreading period that the film has a tendency to shrink. If the film is ruptured with a stirrer, the edges do not weld back together and the film is no longer complete. Observation of the fringes in white light shows that in this situation the film is extremely thin along its edges and does not have a uniform thickness over its whole surface.
The applicants have found to their surprise that this shortcoming disappears when the tertiary amine function of the salts
C.sub.n F.sub.2n.sub.+1 -- (CH.sub.2).sub.a -- COOH, NHR.sub.1 -- (CH.sub.2).sub.p -- N (R.sub.2 R.sub.3)
is quarternized with the help of a lactone ##EQU10## to produce a salt of the formula:
C.sub.n F.sub.2n.sub.+1 -- (CH.sub.2).sub.a -- COO.sup.-,N.sup.+H.sub.2 R.sub.1 -- (CH.sub.2).sub.p -- N.sup.+R.sub.2 R.sub.3 -- (CH.sub.2).sub.q -- COO.sup.- (IV)
not only are the spreading speed and foaming power increased as compared to the results obtained with the binary mixtures of the compounds of Formula I and II alone, but in addition a uniform film which cannot be torn and which is extremely stable results.
The film-forming power PF t of the films is characterized by the ratio of the evaporation speed of the solvent measured with and without the fluorinated film under experimental conditions otherwise identical: ##EQU11##
This index corresponds to the time interval occuring between the beginning the formation of the film and the time of measurement.
It is also possible to measure the film forming power of the solutions by comparison with cyclohexane. For this test, which is more severe than the preceeding one, the same material as in the determination of the spreading speed is used. The formation of the film is obtained by spreading, with the aid of a syringe, 0.1 cc of surface-active solution over the entire surface of the hydrocarbon. The results are expressed in the same way as above.
The fire-extinguishing compounds of the invention can be measured for the impermeability to flame and for the resistance to reignition by the following tests:
Impermeability To the Flame
80cc of cyclohexane are placed in a flat bottomed stainless steel vessel having 150 millimeters in diameter and 32 millimeters in height. 0.1cc of the surface-active solution are deposited at the center of the surface of the cyclohexane and thirty seconds later an additional 0.15cc of the solution are distributed with help of a syringe over the entire surface of the sample. After one minute a microflame is placed in the center of the vessel, 25 millimeters from the surface of the cyclohexane, and one measures the elapsed time prior to ignition or flaming of the hydrocarbon.
Resistance to Reignition
This test measures the behavior of the film vis-a-vis the fire, namely fire retardant action by generation of water vapor and protective action by self-spreading. The test is carried out after the completion of the preceeding test by bringing the microflame into contact with the surface at a location on the wall of the vessel. The time is measured from when the cyclohexane begins to burn until the region of combustion spreads to one half the surface of the sample.
Applicant has determined that in the case of compositions having as a base mixtures of the fluorinated ampholyte surfactant of Formula I, the non-ionic fluorinated surfactant of Formula II, and the quaternized fluorinated diamine salt of Formula IV, the spreading speed of the film has two maximum values which are functions of the proportions of the constituents.
This completely unexpected variation in the speed of spreading as a function of the composition of the mixtures, for a given total concentration of fluorinated surface-active material, shows the existence of a region of concentrations which produce particularly efficacious compositions.
The results gathered together in Table 4 below show that, for solutions composed of mixtures of products I 1 , II 1 and IV 1 these concentrations are located between 36 and 55.2 percent for the ampholyte composition of Formula I 1 , between 24 and 36.8% for the non-ionic compound of Formula II 1 , between 8 and 40% for the diamine salt of Formula IV 1 quaternized with propiolactone.
C.sub.6 F.sub.13 C.sub.2 H.sub.4 COO.sup.-, NH.sup.+.sub.3 -- (CH.sub.2).sub.3 N.sup.+ (CH.sub.3).sub.2 CH.sub.2 --CH.sub.2 -- COO.sup.-(IV.sub.1)
table 4______________________________________volumes of aqueous 0.5% solutions in cm.sup.3Ampholyte fluori- Non-ionic fluori- Quaternized Spreadingnated constituent nated constituent diamine salt speed inI.sub.1 II.sub.1 IV.sub.1 seconds______________________________________30 20 0 1229.4 19.6 1 828.8 19.2 2 3028.2 18.8 3 1227.6 18.4 4 627 18 5 524 16 10 518 12 20 5.512 8 30 306 4 40 no spreading______________________________________
The extent of the most advantageous region diminishes with increase of the ratio by weight of the fluorinated ampholyte constituent to the non-ionic fluorinated constituent. When the value of this ratio is increased from 1.5 to 4, the limits of the most advantageous concentrations take on the following values:
(for a total concentration in fluorinated products of 0.5%)fluorinated ampholyte constituent 64-73%non-ionic fluorinated constituent 16-19%quaternized diamine salts 8-20%
The total 0.5% concentration used in the tests above described by the applicant does not constitute a lower limit, and good film forming properties can be obtained with aqueous solutions having a total of 0.1% to 2% of fluorinated mixture.
In the use of the fire extinguishing compositions of this invention it is often advantageous from an economic point of view to use the three compounds I 1 , II 1 and IV 1 derived from the same fluorinated acid:
C.sub.n F.sub.2n.sub.+1 -- (CH.sub.2).sub.a -- COOH.
it is however likewise possible without adverse affect on the results obtained, to use mixtures of the derivatives I, II and III or IV obtained from different fluorinated acids.
Examples 1-4 give the mode of preparation of fluorinated products used in preparing fire extinguishing compositions according to this invention. Examples 5-12 illustrate these compositions in examplary manner and examples 13, 14 and 15 illustrate their film-forming properties and their effectiveness in extinguishing fires and slowing the evaporation of hydrocarbons.
EXAMPLE I
The fluorinated ampholyte surface-active agent
C.sub.8 F.sub.17 -- C.sub.2 H.sub.4 -- CONH -- (CH.sub.2).sub.3 N.sup.+(CH.sub.3).sub.2 --CH.sub.2 --CH.sub.2 --COO.sup.-
is prepared by addition of the β-propriolactone or of acrylic acid to the polyfluoroamine ##EQU12##
EXAMPLE 2
150cc of xylene, 300 grams (0.755mole) of the acid C 6 F 13 C 2 H 4 COOH, 268 grams (0.755 mole) of the polyethoxylated alkylated alcohol HO(CH 2 --CH 2 --O) 7 CH 3 sold by Produits Chimiques Ugine Kuhlmann under the name EMKANOL M350, and 0.74 grams of concentrated sulfuric acid, were introduced into a one liter pyrex reactor equipped with a stirrer, tube for the introduction of nitrogen, and an extraction device of the DEAN and STARCK type surmounted with an ascending refrigerant. The mixture was heated with reflux and subjected to a slow scavenging with nitrogen, and after four hours the theoretical quantity of water was recovered. The xylenic solution was clarified by refluxing for a quarter of an hour in the presence of 10 grams of activated carbon. After filtration and evaporation of the solvent, 525 grams of a viscous yellow liquid were recovered having the formula
C.sub.6 F.sub.13 C.sub.2 H.sub.4 COO (CH.sub.2 --CH.sub.2 --O).sub.7 CH.sub.3
with a yield of 95%.
EXAMPLE 3
39.2 grams (1/10 mole of C 6 F 13 C 2 H 4 COOH acid were dissolved in 80cc of ethyl acetate and neutralized with 10.2 grams (1/10 mole) of N-dimethylpropanediamine 1-3. Infrared analysis of the product obtained after evaporation of the solvent confirmed the formation of a salt of the diamine on the primary amine function, giving the derivative ##EQU13##
The compound was quaternized with β-propiolactone by addition to the reaction mixture of 7.2 grams (1/10 mole) of β-propiolactone and by maintaining this mix at a temperature in the vicinity of 0°C. After a contact time of 2 hours, the solvent was removed and the compound
C.sub.6 F.sub.13 C.sub.2 H.sub.4 COO.sup.- NH.sub.3 .sup.+ -- (CH.sub.2).sub.3 --N.sup.+ (CH.sub.3).sub.2 --CH.sub.2 --CH.sub.2 --COO.sup.-
the structure of which was confirmed by infrared spectometry, was recovered.
EXAMPLE 4
21.4 grams of polyflurosulphonic acid C 6 F 13 C 2 H 4 SO 3 H of 95% purity were dissolved in 150cc of ethyl acetate. 7.45 grams of triethanolamine were added. The precipitated sulfonate was isolated by filtration on a filter crucible and washed twice with 50cc of ethyl acetate. 24 grams of a white product corresponding to the following formula
C.sub.6 F.sub.13 C.sub.2 H.sub.4 SO.sub.3.sup.-, N.sup.+H -- (C.sub.2 H.sub.4 OH).sub.3
were obtained.
EXAMPLE 5
The following mixture was produced including in addition 0.3% of isopropyl alcohol.
______________________________________C.sub.8 F.sub.17 C.sub.2 H.sub.4 CONH--(CH.sub.2).sub.3 N(CH.sub.3).sub.2CH.sub.2 --CH.sub.2 --COO.sup.- 68% by weightC.sub.6 F.sub.13 C.sub.2 H.sub.4 COOH (CH.sub.2 --CH.sub.2 --O).sub.7CH.sub.3 18% by weightC.sub.6 F.sub.13 C.sub.2 H.sub.4 COO--, NH.sub.3.sup.+ --(CH.sub.2).sub.3--N.sup.+(CH.sub.3).sub.2-- CH.sub.2 -- CH.sub.2 -- COO.sup.- 14% by weight______________________________________
The presence of the isopropanol makes it possible to prepare concentrated mixtures of 400 grams per liter which were diluted to a suitable ratio at the time of use. All of the solutions hereinafter considered thus contain the same quantity of this alcohol. The properties of the solution diluted down to 0.5% are as follows:
foaming power: 400ccpH: 5.6dynamic viscosity: 10.5 mPo at 23°Csurface tension: 14.8 dynes/cm at 21°Cinterfaced tension with cyclohexane: 5.9 dynes/cm at 21°C
Since cyclohexane at this temperature possesses a surface tension of 25.5 dyness/cm, this solution has a distinct positive spreading coefficient of +4.8.
______________________________________spreading speed: 7 secondsdrainage speed: 2 minutes 45 seconds After 1 After 10 After 15Film forming power Minute Minutes Minutes______________________________________of the foam with referenceto high test gasoline 0.22 0.26of the solution withreference to cyclohexane 0.18 0.20 0.41______________________________________impermeability to flame: greater than 38 mm.resistance to flame return: 12.5 seconds (reignition) time______________________________________
It will be noted that this extinguishing composition makes it possible to simultaneously obtain good foaming capabilities, high spreading speed and drainage speed, high film-forming properties, high impermeability to flame and high resistance to flame return or low reignition characteristics.
EXAMPLE 6
The following ternary mixture was produced
C.sub.8 F.sub.17 C.sub.2 H.sub.4 COHN--(CH.sub.2).sub.3 --N(CH.sub.3).sub.2 68% by weight--CH.sub.2 --CH.sub.2 --COO.sup.-C.sub.6 F.sub.13 C.sub.2 H.sub.4 COO (CH.sub.2 --CH.sub.2 --O).sub.7CH.sub.3 18% by weightC.sub.6 F.sub.13 C.sub.2 H.sub.4 COO.sup.-NH.sub.3 .sup.+--(CH.sub.2).sub.3 --N(CH.sub.3).sub.2 14% by weight
A 0.5 percent aqueous solution of fluorinated product including 0.3% isopropyl alcohol was prepared from this mixture.
The characteristics of this solution were as follows:
foaming power: 360ccpH: 7.65dynamic viscosity: 13.2mPo at 23°Cspreading speed: 9 secondsdrainage speed: 9 minutes After 1 After 10 After 15Film forming power Minute Minutes Minutes______________________________________of the foam with referenceto high test gasoline 0.66 0.20 0.23of the solution withreference to cyclohexane 0.23 0.45 0.45______________________________________impermeability to flame: 10 minutesresistance to cyclohexane 11 seconds
It will be noted that this fire-extinguishing composition, which includes as a third ingredient a non-quaternized salt of diamine, produces results inferior to those obtained in example 5, particularly with regard to impermeability to the flame, film-forming power, and spreading capacities.
EXAMPLE 7
The following mixture was prepared:
C.sub.8 F.sub.17 C.sub.2 H.sub.4 CONH -- (CH.sub.2).sub.3 N.sup.+(CH.sub.3).sub.2 CH.sub.2 55% by weight--CH.sub.2 --COO.sup.-C.sub.6 F.sub.13 C.sub.2 H.sub.4 COO (CH.sub.2 --CH.sub.2 --O).sub.7CH.sub.3 37% by weightC.sub.6 F.sub.13 C.sub.2 H.sub.4 COO.sup.-, NH.sub.3 .sup.+--(CH.sub.2).sub.3 N.sup.+(CH.sub.3).sub.2 8% by weightCH.sub.2 --CH.sub.2 --COO.sup.-
This mixture was put into an 0.5% aqueous solution.
The solution possessed the following properties:
foaming power: 340ccpH: 5.2dyanmic viscosity: 11.5 mPo at 23°Cspreading speed: 6 seconds (same value after one month) After 1 After 10 After 15Film forming power Minute Minutes Minutes______________________________________of the foam with respect tohigh-octane gasoline 0.27 0.26of the solution with respectto cyclohexane 0.13 0.18 0.32______________________________________impermeability to flame: 12 minutesresistance to reignition: 13 seconds
EXAMPLE 8
From the following mixture:
C.sub.8 F.sub.17 C.sub.2 H.sub.4 CONH--(CH.sub.2).sub.3 N.sup.+(CH.sub.3).sub.2 CH.sub.2 --CH.sub.2 --COO.sup.- 36% by weightC.sub.6 F.sub.13 C.sub.2 H.sub.4 COO (CH.sub.2 --CH.sub.2 --O).sub.7CH.sub.3 24% by weightC.sub.6 F.sub.13 C.sub.2 H.sub.4 COO.sup.-,NH.sub.3 .sup.+(CH.sub.2).sub.3 N (CH.sub.3).sub.2 40% by weight
an 0.5% aqueous solution was prepared having the following properties:
foaming power: 640 ccpH: 8.35dynamic viscosity: 10.2mPo at 23°Cspreading speed: 4.5 seconds (40 seconds after 30 days)drainage speed: 3 minutes (solution 30 days) After 1 After 10 After 15Film forming power Minute Minutes Minutes______________________________________of the foam with respectto high-octane gasoline 0.25 0.15of the solution with respectto cyclohexane 0.26 0.84 1.0______________________________________impermeability to flame: 12 minutesresistance to reignition: 12 seconds
EXAMPLE 9
The following mixture was prepared:
C.sub.8 F.sub.17 C.sub.2 H.sub.4 CONH (CH.sub.2).sub.3 N.sup.+(CH.sub.3).sub.2 CH.sub.2 --CH.sub.2 --COO.sup.- 54% by weightC.sub.6 F.sub.13 C.sub.2 H.sub.4 COO -- (CH.sub.2 --CH.sub.2 --O).sub.7CH.sub.3 36% by weightC.sub.6 F.sub.13 C.sub.2 H.sub.4 COO.sup.-NH.sub.3 .sup.+--(CH.sub.2)N.sup.+(CH.sub.3).sub.2 CH.sub.2 CH.sub.2 COO.sup.- 10% by weight
This mixture was put into an 0.5% aqueous solution. The solution possessed the following properties:
foaming power: 390ccpH: 4.0dynamic viscosity: 10.25mPo at 23°Csurface tension: 15.6 dynes/cm at 21°Cinterfacial tension with cyclohexane:+4.4 dynes/cmspreading speed: 4 secondsdrainage speed: 2 minutes 55 seconds After 1 After 10 After 15Film forming power Minute Minutes Minutes______________________________________of the foam with respect tohigh-octane gasoline 0.25 0.17of the solution with respectto cyclohexane 0.18 0.58______________________________________impermeability to flame: > 15 minutesresistance to reignition: 15.5 seconds
EXAMPLE 10
The following mixture was prepared:
C.sub.8 F.sub.17 C.sub.2 H.sub.4 CONH (CH.sub.2).sub.3 N.sup.+CH.sub.2--CH.sub.2 --COO.sup.- 62% by weightC.sub.6 F.sub.13 C.sub.2 H.sub.4 COO (CH.sub.2 --CH.sub.2 --O).sub.7CH.sub.3 30% by weightC.sub.6 F.sub.13 C.sub.2 H.sub.4 COO.sup.-, N.sup.+H.sub.3 (CH.sub.2).sub.3 N.sup.+(CH.sub.3)CH.sub.2 --CH.sub.2 8% by weight--COO.sup.-
This mixture was put into an 0.5% aqueous solution. The solution possessed the following properties:
foaming power: 450ccpH: 4.05dynamic viscosity: 10.2 mPo at 23°Cspreading speed: 4 secondsdrainage speed: 4 minutes After 1 After 10 After 15Film forming power Minute Minutes Minutes______________________________________of the foam with respect tohigh-octane gasoline 0.28 0.29 0.30of the solution with respectto cyclohexane 0.18 0.37 0.45______________________________________impermeability to flame: > 10 minutesresistance to reignition: 12 seconds
EXAMPLE 11
The following mixture was produced:
C.sub.8 F.sub.17 C.sub.2 H.sub.4 CONH--(CH.sub.2).sub.3 N.sup.+(CH.sub.3).sub.2 CH.sub.2 --CH.sub.2 --COO.sup.- 60% by weightC.sub.6 F.sub.13 C.sub.2 H.sub.4 COO(CH.sub.2 --CH.sub.2 --O).sub.7CH.sub.3 40% by weight
An 0.5% solution of this mixture produced the following properties:
foaming power: 130ccpH: 4.95surface tension: 17.7 dynes/cmspreading speed: 13 seconds
This example shows that poorer results are obtained only when there is used a mixture of the two first constituents of the extinguishing compositions according to the invention.
EXAMPLE 12
The following mixture was prepared:
C.sub.8 F.sub.17 C.sub.2 H.sub.4 CONH -- (CH.sub.2).sub.3 N.sup.+(CH.sub.3).sub.2 CH.sub.2 --CH.sub.2 83% by weight--COO.sup.-C.sub.6 F.sub.13 C.sub.2 H.sub.4 SO.sub.3 .sup.-, N.sup.+H (CH.sub.2H.sub.4 OH).sub.3 17% by weight
This mixture was put into an 0.5% aqueous solution. The solution possessed the following properties:
foaming power: 100ccpH: 6.15dynamic viscosity: 34.5 mPo at 23°Csurface tension: 14.3 dynes/cmspreading speed: 35 secondsdrainage speed: >30 minutes
EXAMPLE 13
0.36% and 0.10% solutions of the mixture described in EXAMPLE 7 were prepared and the film forming properties of the solutions with reference to cyclohexane were determined.
After 1 After 10 After 15Concentration Minute Minutes Minutes______________________________________0.36 % 0.19 0.27 0.460.10 % 0.32 0.70 0.93______________________________________
These results show that with the composition of EXAMPLE 7 one should not go to total concentrations of fluorinated products below 0.1%, if it is desired to retain a good film forming property.
EXAMPLE 14
Extinction of a type 233Bl fire (tub 3 meters in diameter having 7 square meter surface and containing 233 liters of domestic fuel oil) was attained in 22 seconds by use of 0.22% solution of the mixture described in EXAMPLE 10. The fire extinguisher employed was of the type producing a waterspray and the fire was attacked after one minute of burning.
EXAMPLE 15
Three one-liter beakers A, B, and C each 110 millimeters in diameter were partly filled with 900 cc of cyclohexane. In beakers B and C on the surface of the cyclohexane, 0.1cc of the film-forming solutions described in EXAMPLE 5 and 10 respectively were placed. Beaker A served as a reference and the rate of evaporation of the hydrocarbon was measured in all three beakers. The results obtained are summarized in table 5 and show the power of the products of the invention to retard evaporation of hydrocarbons
Time A B C______________________________________3 days 17.8% 3.3% 3.9%5 days 30.4% 5.5% 6.1%7 days 42.3% 8.3% 8.3%______________________________________ | 4y
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Modular system of closet inside part or dressing room complement of combinable design mass manufactured, of adjustable and standardized sizes according to the needs of modern popular or residential buildings, characterized because it is easy to assemble, highly resistant to impacts or items overload, and makes optimum use of wardrobe and other items spaces, with or without lateral edge reinforcement.
[0003] 2. Description of the Previous Art
[0004] Several closet construction designs are known, such as the assembling of pieces or modules generally of solid wood, fine wood or pine wood. For example, British Patent 640,518, describes a dismountable closet based on a module with lateral and back walls formed as one single unit. Japanese Patent 5141080 describes the building structure of a closet based on a smaller member of parts through the use of grooved posts for the assembly of the lateral walls.
[0005] U.S. Pat. No. 5,718,490 describes a portable dismountable closet for travels, characterized because it has a textile cover on a supporting tubular structure for assembly purposes.
[0006] U.S. Pat. No. 4,209,099 describes a support module for closet to increase the usable space in the closet, based on bars placed in horizontal or vertical positions and assembled on collapsible cylindrical pipes through connecting elements with intersection joints.
[0007] Japanese Patent 5098791 describes the formation of a closet through the assembly of wooden frame shaped panels with heat insulation structure with “U” shaped sections and fixed onto posts, forming units.
[0008] U.S. Pat. No. 6,079,803 describes a system of closet organization and a method for its installation, characterized because it features the assembly of a console unit, the unit having tubular plastic posts to include additional racks.
[0009] U.S. Pat. No. 6,113,208 describes a self-assembly closet, that uses clip elements to fasten the shelves onto the lateral parts of the closet through a tongued and grooved assembly.
[0010] The above-mentioned inventions are generally characterized because they propose adjustable closets that can be assembled and dismounted. The invention relates to pieces of furniture such as closets, book shelves, etc. made of agglomerated-wood based materials that, through various manufacturing techniques, are made as resistant and durable as the pieces of furniture made of solid material. Moreover, said pieces of furniture can be assembled, dismounted and adjusted to the space available according to popular or residential building standards.
[0011] The instant invention is an embodiment of the manufacturing kit for closet inside part such as described in our Mexican Patent Application PA/a/2003/004388
DESCRIPTION OF THE INVENTION
[0012] Hereinafter the invention will be described according to FIGS. 1 to 10 wherein:
[0013] [0013]FIG. 1 corresponds to a perspective view of a module (ECO) assembled in two different versions: a, b and first combination (ECO+ROD) of the closet inside part.
[0014] [0014]FIG. 2 corresponds to a perspective view of a module (UCO) assembled in three different versions: a, b and c of the closet inside part.
[0015] [0015]FIG. 3 corresponds to a perspective view of module EL 4 assembled in two versions: a, b and a combination EL 4 +ROD of the closet inside part.
[0016] [0016]FIG. 4 corresponds to a perspective view of a module (ECO) assembled in two combinations (ECO+EL 4 ) a, and (ECO+UCO+TAP) b of the closet inside part.
[0017] [0017]FIG. 5 corresponds to a perspective view of an assembly combination (UCO+TAP+ROD) of the closet inside part.
[0018] [0018]FIG. 6 corresponds to a perspective view of the assembly of two combinations (UCO+2ROD) a, and (ECO+ROD+UCO+TAP) b of the closet inside part.
[0019] [0019]FIG. 7 corresponds to a perspective view of FIG. 6, including chests of drawers.
[0020] [0020]FIG. 8 corresponds to a perspective view of a dressing room of 1.83 m/3.05 m with modules (ECO+2UCO+TAP+ROD) arranged placed in an “L” shape.
[0021] [0021]FIG. 9 corresponds to a perspective view of a square dressing room of 1.83 m/1.83 m with front side views a, b, c and top view d, with modules (ECO+2UCO+TAP+ROD).
[0022] [0022]FIG. 10 corresponds to a perspective view of a rectangular dressing room, 1.83 m/1.22 m with front side views a, b, and top view c, with modules (EC+UCO+TAP).
GENERAL CHARACTERISTICS OF THE INSIDE PARTS OF THE CLOSETS
[0023] MODULES UCO, ECO and EL 4
[0024] Every package contains all the elements necessary to place a full modular system of the closet inside part within a previously available enclosure, the width of which will be within the width parameters mentioned as most important information on the package. Shelves, sections of vertical screens, hanging pipes and all the supports and assembly elements as well as wall fastening elements are included. To adjust the product to the size of the existing enclosure, the user only needs to cut the hanging pipes.
[0025] The vertical screens measure, in depth, only half the depth of the deepest shelves. Besides, the vertical screens are away from the back wall and in this way it is possible to keep the clothes placed on the shelves through the sides and at the same time what is placed on the shelves can be seen till the contact with the back wall, making it easier to clean. Clothes are ventilated in the deepest part, preventing stuffing which favors insect multiplication, fungus growth or moisture accumulation.
[0026] In this design, the vertical screens of the closets are separated from the back wall and because of this it is possible to place the closet without taking into account whether there is or not a skirting board in the area of the installation. If the screens were in contact with the back wall, it would be necessary to cut them or to cut the skirting board if there were one.
[0027] There are rooms, with or without skirting board, that have spiked wooden strips below the carpet for carpet placement. The separation of the screens with regard to the back wall permits to place the screen base on the floor. If the vertical screens were placed in contact with the back wall, only the back part of said screens would be on the spiked wooden strips used to place the carpet while the rest of the screen base would not be supported. The placement of the vertical screens away from the back wall makes it easier to adequately spread the weight of the closet and the load of the items placed in the closet and the load received by the hanging pipes that support hanging clothes avoiding in this way a possible maladjustment or deformation of the structure of the closet inside part.
[0028] For the user it is important to carry a relatively light package. Because it has vertical screens that are only half as deep as a deepest shelves, the weight corresponding to the screens is divided by half.
[0029] Because they measure half the depth of the deepest shelves, two pieces of vertical screen fit in only one layer of materials within the box instead of two layers of materials and thus the package is more compact.
[0030] It is possible to place each one of the closet inside parts individually within an existing enclosure or combine them, in pairs or the three of them together, depending on the width of the enclosure in which the user wishes to place the closet and his preferences
[0031] The three models of closet inside parts have the option of cutting the segment of the hanging pipe included in the package in two segments half the original length and to place both segments on one side of the enclosure. In this way, with said three models, various solutions are offered to take advantage in different ways of the space with different closet inside parts that are adequate for the width of the smallest common enclosures in the market, such as in the case of social housing. As can be observed hereinafter, it is possible to add to the UCO model the set of shelves model TAP that can be used as shoe rack, and using the UCO model, it is possible to create a closet enclosure without a wall on one side.
[0032] The three closet inside parts are adequate to have as accessory a hanging pipe segment model ROD, which, because it is equal to the hanging pipe segment included in each one of the three packages, increases the clothes hanging capacity. The three inside parts of closets and their combinations, once placed, permit the placement of a shelf from to wall to wall that is not part of the system. Said shelves can also be placed only above the hanging pipes and supported on the vertical screens. In a similar way, instead of said shelves, on the vertical screens of the three closet inside parts, individually or in combination, it is possible to place a closet roof, which is an unbroken shelf from wall to wall and deep enough to place closet doors that are at least flush with the same and leave enough depth in the closet inside part for the hanging clothes. This type of roofs are common in the cases of heights much higher than 2.40 meters from floor to ceiling, a case which is most common in the case of the upper floor of a gable roof house. In these cases, the client can keep more items than the ones fitting in the closet inside part, placing them on the roof of the closet and taking advantage of the free space on said roof, although said items are visible.
[0033] [0033]FIG. 1.—According to the drawings of the module (ECO)a and b, said module comprises an upper shelf tower 10 , one or several hanging pipe elements 11 and support elements 12 to fasten the hanging pipes; it also includes one or two vertical screens 13 placed on one side or on both sides of the tower 10 and comprising an assembly of two panel sections A and B, with or without lateral edge reinforcements through plastic structured profiles or only by screwing with specially designed screws forming only one piece. The two-section screen 13 has the advantage of being available in only one package, that has moreover for the user the characteristic of having the same shelf thickness 14 of the tower 10 and thus the weight of the modular system is lower, packed in a compact volume and easy to carry by the user. The module (ECO) is available in two embodiments a and b, being the (a) module available in sizes 1.83 m width by 1.22 m. In another of its embodiments (ECO+ROD), with two short hanging elements 11 and a long one, it can be available in 1.22 m or 1.83 m width, the height being conventional according to the floor-ceiling distance which is usually 2.40 m.
[0034] The vertical screens are half as wide as the depth of the shelves 11 and said shelves are fastened at mid depth in such a way that they are spaced with regard to the enclosure, i.e. they are not fastened touching the wall of the enclosure.
[0035] [0035]FIG. 2.—The module (UCO) has three embodiments a, b and c i.e. with different widths (UCO)a: 1.83 m; (UCO)b: 1.22 m and (UCO)c: 1.43 m. All of them have a tower 10 with shelves 14 and hanging elements 11 as well as double screen 13 , which permits to combine the tower with different arrangements a, b and c according to the needs of the user.
[0036] [0036]FIG. 3.—The module (EL 4 ) also has three embodiments (EL 4 )a: 1.83 m wide, and long hanging element 11 , four shelves 14 equidistantly placed and only one screen; (EL 4 )b: 1.22 m., two hanging elements 11 , and four shelves 14 and fastening elements 12 , and only one screen 13 of tower 10 ; and a combination of (EL 4 +ROD) which is 1.83 meters wide with two hanging elements 11 .
[0037] [0037]FIG. 4.—The module (ECO+EL 4 )a forms a new design with two laterally arranged shelf tower 10 and in between with two hanging elements 11 , being the left side tower formed by two upper shelves 14 and a screen, while the right lateral side of the tower consists of four shelves equidistantly placed fastened by a second screen 13 and fastening elements 11 onto the walls of the enclosure and screens.
[0038] The second combination (ECO+UCO+TAP)b comprises a new module with two shelves towers 10 similarly arranged as the previous module having the characteristic of including in the UCO module a larger number of lower shelves (TAP).
[0039] Both the (ECO+EL 4 )a module and the (ECO+UCO+TAP)b module have a width of 2.44 m.
[0040] [0040]FIG. 5.—The module presents the combination of three modules (UCO+TAP+ROD) integrated by a tower with upper and lower shelves 14 based on two screens, and two hanging elements and fastening elements 12 onto the walls of the enclosure and screen width of 1.83 m.
[0041] [0041]FIG. 6.—The module presents two combinations, one being (UCO+ 2 ROD)a, based on a shelf tower 10 placed at the center with four shelves 14 equidistantly placed, with two lateral screens 13 , two hanging lateral elements 11 , being the one of the left with double hanging 11 and the one of the right with only hanging elements 11 , and 3.05 m wide. The combination module (ECO+ROD+UCO+TAP)b consists of two shelves towers 10 , the left one with two upper shelves and the right one with three shelves 14 equidistantly distributed in the upper intermediate part, and in the lower part it includes three shelves 14 for shoes (TAP), the towers are integrated by three screens 13 . Between said towers 10 , a hanging module larger than the towers (c) is incorporated, having two hanging elements 11 , while the right lateral hanging module D is smaller but also has two hanging elements 11 and the left lateral module E has one long clothes hanging element 11 , and fastening elements for the walls and screens, being the module 3.05 m wide.
[0042] [0042]FIG. 7.—This module is a combination of the module of FIG. 6 with chests of drawers 15 which can be included in any of the (UCO) type modules.
[0043] [0043]FIG. 8.—This module includes a combination a and b for dressing room based on (ECO+2 UCO+TAP+ROD) modules arranged in an “L” shape in a space 1.83 m. deep and 3.05 m. long. Each one of the modules is mass manufactured and available in one single modular system packed in such a way that the user can choose the sizes according to his or her needs.
[0044] [0044]FIG. 9.—This module is applicable to small space dressing room, i.e. 1.83 m/1.83 m and is combined with modules (ECO+2 UCO+TAP+ROD)a, b and c.
[0045] [0045]FIG. 10. This module is for a small rectangular dressing room 1.83/1.22 m and is combined with modules (ECO+UCO+TAP)a and b.
Characteristics of the Modular System Package
[0046] The package features a picture of the installed and assembled product in an adequate space and presenting several items corresponding to a house wardrobe. In said picture, the high design efficiency of the modular system is shown taking advantage of the width and height of the available space.
[0047] On the package, an exploded view of the pieces forming it is shown to communicate to the user the contents of the box (the drawing omits the assembling and installation fittings that are only mentioned with letters)
[0048] The package shows the recommended width parameters, the advantages of the product, some combinations with other products and the options of the adjustment to the width of several existing enclosures. The architectonic design offers design solutions for the most varied closet enclosures with the most efficient storage, exhibition and transportation method.
[0049] The arrangement of the pieces inside the packing box permits that the contents support the compression and the load of the boxes placed above avoiding the crushing of the packages.
[0050] The size of the boxes permits to stow them on standard 40″×48″ pallets which are placed according to well established patterns for warehouse storage standard structures, within marine containers, piggy backs, trailer and other long distance transportation means. There are hydraulic skates, weight lifters and other devices to move them easily.
[0051] The boxes can be placed and transported vertically on said standard pallets to be taken to the market centers so that the user can easily handle a compact packing box in his or her own vehicle.
[0052] On the packing boxes there are instruction leaflets which are understandable without the need to read the texts. In such a way it is not important if the installer can read or not or whether he understands one of the three languages in which the texts are written or not.
[0053] The boxes and the labels are printed in colors which are characteristic of each model and the short and clear keys on the products are shown in a large size on all the sides of the boxes, so that they are easily identifiable and can be seen even if they are high up on metal storage structures, for example.
[0054] The advantages of the described invention have been presented in an economical and practical manner Although specific embodiments and example configurations have been described, it is to be understood that various modifications and additional configurations will be apparent to the skilled in the art. It is intended that the specific embodiments and configurations herein are illustrative of the preferred and best modes for practicing the invention, and should not be interpreted as limitations on the scope of the invention as defined by appended claims. | 4y
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BACKGROUND OF THE INVENTION
Motor vehicles are known which can be shifted from rear-wheel drive to four-wheel drive, for example, and in which the drives of the two axles can be rigidly coupled to each other by locking the associated differential. In addition, one or two differential locks may be provided for the rigid coupling of the wheel drives of one axle.
Moreover, anti-lock braking systems for motor vehicles are known which, for the control of the wheel slip, form a reference value whose curve optimally approximates that of the vehicle speed. In such system this reference value is formed by the use of different gradients.
The formation of the reference value is particularly difficult in the case of vehicles with four-wheel drive, and especially when, in addition, a central lock is engaged.
SUMMARY OF THE INVENTION
The principal object of the invention and its embodiments is to provide possible solutions for the problem outlined above. In this connection, it is important that the central lock and any further locks which may be used, as well as the four-wheel drive, be disengaged or defeated as the brakes are applied. This may be done in response to the brake light switch signal.
This object, as well as other objects which will become apparent from the discussion that follows, are achieved, in accordance with the present invention, by varying the reference value in dependence upon whether the motor vehicle is shifted into two-wheel or four-wheel drive, in dependence upon the engagement of a central lock, and/or in dependence upon the engagement of a differential lock.
For a full understanding of the present invention, reference should now be made to the following detailed description of the preferred embodiments of the invention and to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the power train and electronic control system for a four-wheel drive vehicle.
FIG. 2 is a block diagram of an anti-lock braking system according to the present invention, as applied to the vehicle of FIG. 1.
FIG. 3 is a block diagram showing a typical evaluation circuit which may be used in the system of FIG. 2.
FIG. 4 is a time diagram illustrating the operation of the anti-lock braking system of FIGS. 2 and 3 in one driving situation.
FIG. 5 is a time diagram illustrating the operation of the anti-lock braking system of FIGS. 2 and 3 in another driving situation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An exemplary embodiment of the invention is illustrated in FIGS. 1 to 3, and various possible solutions are illustrated in FIGS. 4 and 5 in terms of two driving situations.
In FIG. 1, the front wheels of a motor vehicle are designated by 1 and 2, and its rear wheels by 3 and 4. An engine 5 is normally connected through a drive shaft 10 with a differential 6 through which the rear wheels 3 and 4 are driven.
In the vehicle shown in FIG. 1, provision is made for shifting to four-wheel drive, to which end a longitudinal differential 7 can be switched so that in addition to the shaft 10 for the rear-wheel drive a shaft 8 is driven, through which and through a further differential 9 the front wheels are driven.
The shafts 8 and 10 can be rigidly coupled to the engine through a central lock contained in the differential 7. The differentials 6 and 9 may also have differential locks that can be engaged.
The assumption is here made that the shifting to four-wheel drive and the engagement of the locks are brought about automatically by means of a control circuit 11 to which signals corresponding to the speeds of the wheels 1 to 4 are fed. (This is indicated in FIG. 1 only by the wheel speed sensors 2a and 4a for the wheels 2 and 4, respectively. Corresponding wheel speed sensors 1a and 3a are also connected to the control circuit 11.) On the basis of the wheel-speed differences ascertained, a shifting to four-wheel drive and/or an engaging of the differential locks occurs, triggered by means of lines 13. A brake light switch signal is fed to the terminal 12 for releasing the locks and disengaging the four-wheel drive.
Shown in FIG. 2 is the associated anti-lock braking system, consisting of the four wheel-speed sensors 1a to 4a, an evaluation circuit 20, brake-pressure control units 21 and 22 for the two front wheels 1 and 2, and a single brake-pressure control unit 23 for the rear wheels 3 and 4.
Also shown in FIG. 2 is the control circuit 11 from FIG. 1, to which the signals of the sensors 1a to 4a are fed, and which delivers the switching signals for the four-wheel drive and the differential locks by way of the terminals 24 to 27. The switching signals at the terminals 26 (for four-wheel drive shifting) and 27 (for the central lock) are also fed to the evaluation circuit to enter into the formation of the reference value.
FIG. 3 is a basic diagram showing the formation of slip in the evaluation circuit 20 of FIG. 2. The wheel-speed signal of one of the sensors 1a to 4a is fed to a terminal 30 and then to a reference-value former 31 and a comparator 32. Switching signals for the four-wheel drive (terminal 34) and for engagement of the central lock (terminal 35) are further fed to the reference-value former 31.
The reference value produced by the latter is compared in the comparator 32 with the wheel-signal, and a broke pressure-reduction signal is generated at a terminal 33 when the wheel-speed signal falls below the reference-speed signal.
The diagram of FIG. 4 illustrates the mode of operation of the reference-value former 31 of FIG. 3 for the driving situation in which the vehicle starts to climb a hill with the wheels spinning. Curve 40 shows the wheel speed, curve 41 the vehicle speed, and curves 42a, 42b and 42c different (alternative) reference values.
The driving situation starts at t o . At t 1 , shifting to four-wheel drive occurs automatically since the wheels are spinning (The vehicle speed 41 remains practically zero). This illustrates the case where the gradient of the reference speed 42 is limited and of the same magnitude (e.g., 0.2 grade) whether the four-wheel drive is engaged or not. Since the wheels continue to spin, the central lock is engaged at t 2 . Now the reference value is either held constant (curve 42a) or then increased just slightly and continuously (not illustrated), reduced with a constant gradient (curve 42b), or set at a minimal speed (curve 42c; here approximately equal to the vehicle speed). This state persists until the brakes are applied at t 3 (see brake light switch signal BLS) and the wheel speed is consequently reduced. At t 3 the central lock is released and the four-wheel drive is also disengaged. The reference value now can rise with a given gradient of about 0.2 to 0.4 gr (course 42' in curve 42a; course 42" in curves 42 b and 42c). At t 4 , the wheel-speed signal (40) drops below the reference value (42'), and a brake pressure-reduction signal (AV) is now generated at the terminal 33. At the same time the reference value is reduced with a given negative gradient of about 0.3 to 0.4 gr.
The brake pressure reduction here brought about actually occurs only rarely or, when it does, only momentarily. This would not be the case if the reference value were allowed to rise further, as in the range from t o to t 2 , which would result in a temporarily depressurized brake.
In the case of the reduction proposed according to curve 42b and 42", the advantage described in enhanced, and in the case of curve 42c and 42" it is even less likely that the brake pressure will be reduced. In the case of the last-mentioned curve, but also in the case of curve 42b with an appropriate negative gradient, the reference speed cannot exceed the vehicle speed even when the vehicle decelerates, with the central lock engaged.
The vehicle speed will not be appreciably exceeded by the reference speed even with the central lock momentarily released (for example, to check whether engaging the lock is still appropriate). In the case of curve 42b and 42", even spurious signals indicating an engaged central lock will not appreciably distort the reference.
In FIG. 4, the assumption is made that the gradient is the same with and without four-wheel drive. Actually, the reference value could be allowed to rise with a steeper gradient during the period from t o to t 1 (as is usually the case with ABS). However, there is then the risk that if the shifting to four-wheel drive is not recognized, the reference signal will increase too much and a long-lasting pressure-reduction phase will also result.
FIG. 5 is based on the assumption that the vehicle is about to climb a hill, with the wheels at first spinning but then reaching ground with a higher coefficient of friction (μ). The wheel-speed curve is denoted by 50, and the reference-speed curve (or the corresponding signal curve) by 52 (with the different characteristics 52a to 52c and 52' and 52", respectively).
The vehicle is to start moving at t o , but since the wheels are spinning the vehicle speed 51 remains practically zero. At t 1 , shifting to four-wheel drive occurs; however, in this example also, the gradient of the reference speed is not changed. Only at time t 2 , when the central lock is engaged, does one of the optional reference curves 52a or 42c of FIG. 4, provided as alternatives, become effective. At time t 3 , the wheel reaches high-μ ground and is at first decelerated until the slip ceases (at t 4 ). Here the vehicle speed has caught up with the wheel speed, and both speeds increase in unison until the brake is applied at t 5 (BLS signal).
Between t 2 and t 5 , the reference speed has taken a selected course according to the curves 52a to 52c. From t 5 onward, the reference speed increases according to curves 52',/52" with a given positive gradient (about 0.2 to 0.4 gr). At the same time, the four-wheel drive and the locks were here disengaged.
From t 5 onward, pressure-reduction signals AV are generated by the wheel-speed oscillations due to the deceleration until (at t 6 ) pressure-reduction signals are generated also by the slip.
In the case of FIG. 5, the curve 52a and 52", or the case of the slight increase in the reference, not shown here, is preferred since the reference catches up with the wheel speed sooner.
The increase in the reference after the application of the brakes is advantageous in the case of FIG. 5 but a drawback in the case of FIG. 4. As a compromise, a small gradient (e.g., 0.3 to 0.4 gr) is preferably selected.
There has thus been shown a novel anti-lock braking system which fulfills all the objects and advantages sought therefor. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this specification and the accompanying drawings which disclose the preferred embodiments thereof. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow. | 4y
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RELATED APPLICATION
[0001] The present invention claims priority to U.S. Provisional Patent Application No. 60/364,803 filed Mar. 15, 2002 entitled “Latching Micro-Regulator”, the contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a micro-regulator and a bi-stable latching valve for regulating fluid flow on micro-scale dimensions.
BACKGROUND OF THE INVENTION
[0003] In the chemical, biomedical, bioscience and pharmaceutical industries, it has become increasingly desirable to perform large numbers of chemical operations, such as reactions, separations and subsequent detection steps, in a highly parallel fashion. The high throughput synthesis, screening and analysis of (bio)chemical compounds, enables the economic discovery of new drugs and drug candidates, and the implementation of sophisticated medical diagnostic equipment. Of key importance for the improvement of the chemical operations required in these applications are an increased speed, enhanced reproducibility, decreased consumption of expensive samples and reagents, and the reduction of waste materials.
[0004] Microfluidic devices and systems provide improved methods of performing chemical, biochemical and biological analysis and synthesis. Microfluidic devices and systems allow for the performance of multi-step, multi-species chemical operations in chip-based micro chemical analysis systems. Chip-based microfluidic systems generally comprise conventional ‘microfluidic’ elements, particularly capable of handling and analyzing chemical and biological specimens. Typically, the term microfluidic in the art refers to systems or devices having a network of processing nodes, chambers and reservoirs connected by channels, in which the channels have typical cross-sectional dimensions in the range between about 1.0 μm and about 500 μm. In the art, channels having these cross-sectional dimensions are referred to as ‘microchannels’.
[0005] By performing the chemical operations in a microfluidic system, potentially a number of the above-mentioned desirable improvements can be realized. Downscaling dimensions allows for diffusional processes, such as heating, cooling and passive transport of species (diffusional mass-transport), to proceed faster. One example is the thermal processing of liquids, which is typically a required step in chemical synthesis and analysis. In comparison with the heating and cooling of liquids in beakers as performed in a conventional laboratory setting, the thermal processing of liquids is accelerated in a microchannel due to reduced diffusional distances. Another example of the efficiency of microfluidic systems is the mixing of dissolved species in a liquid, a process that is also diffusion limited. Downscaling the typical dimensions of the mixing chamber thereby reduces the typical distance to be overcome by diffusional mass-transport, and consequently results in a reduction of mixing times. Like thermal processing, the mixing of dissolved chemical species, such as reagents, with a sample or precursors for a synthesis step, is an operation that is required in virtually all chemical synthesis and analysis processes. Therefore, the ability to reduce the time involved in mixing provides significant advantages to most chemical synthesis and analysis processes.
[0006] Another aspect of the reduction of dimensions is the reduction of required volumes of sample, reagents, precursors and other often very expensive chemical substances. Milliliter-sized systems typically require milliliter volumes of these substances, while microliter sized microfluidic systems only require microliter volumes. The ability to perform these processes using smaller volumes results in significant cost savings, allowing the economic operation of chemical synthesis and analysis operations. As a consequence of the reduced volume requirement, the amount of chemical waste produced during the chemical operations is correspondingly reduced.
[0007] In microfluidic systems, regulation of minute fluid flows through a microchannel is of prime importance, as the processes performed in these systems highly depend on the delivery and movement of various liquids such as sample and reagents. A flow control device may be used to regulate, allow or halt the flow of liquid through a microchannel, either manually or automatically. Regulation includes control of flow rate, impeding of flow, switching of flows between various input channels and output channels, as well as volumetric dosing. It is generally desirable that flow control devices, such as valves, precisely and accurately regulates fluid flow, while being economical to manufacture.
SUMMARY OF THE INVENTION
[0008] The present invention provides a latching micro-regulator for regulating liquid flow on micro-scale levels. The latching micro-regulator provides binary addressable flow control using digital latching. The latching micro-regulator includes a bi-stable latching valve comprising a substrate having an inlet port and an outlet port, a valve seat defining a valve chamber for opening and closing the inlet port, and an actuator assembly for actuating the valve element. The valve chamber is configured to contain a volume of fluid, and the inlet port and the outlet port are in fluid communication with the valve chamber to provide a liquid flow path through the chamber. The actuator assembly comprises a cantilever beam for moving the valve seat between an open position and a closed position, an actuator, such as a piezoelectric element, for moving the cantilever beam, and a latch, such as a permanent magnet, for securing the cantilever beam in the closed position.
[0009] According to a first aspect of the invention, a bi-stable latching valve for controlling fluid flow through a channel is provided. The bi-stable latching valve comprises a substrate defining an inlet port and an outlet port in communication with the channel, a valve seat, an actuator assembly for selectively moving the valve seat between the open position and the closed position and a latching mechanism. The valve seat defines a valve chamber in communication with the inlet port and the outlet port for containing a volume of fluid and the valve seat moves between a closed position wherein the valve seat blocks one of said inlet port and said outlet port and an open position to allow fluid flow through the valve chamber to regulate fluid flow through the chamber. The latching mechanism latches the valve seat in one of said open position and closed position.
[0010] According to another aspect, a flow regulating system is provided. The flow regulating system comprises a first flow channel for conveying liquids having a first flow resistance, a first bi-stable valve in communication with the first flow channel for selectively blocking liquid flow through the first flow channel, a second flow channel for conveying liquids having a second flow resistance and a second bi-stable valve in communication with the second flow channel for selectively blocking liquid flow through the second flow channel.
[0011] According to yet another aspect, a flow regulating system is provided. The flow regulating system comprises a first flow channel for conveying liquids having a first flow resistance, a first bi-stable latching valve in communication with the first flow channel for selectively blocking liquid flow through the first flow channel, a second flow channel for conveying liquids having a second flow resistance and a second bi-stable latching valve in communication with the second flow channel for selectively blocking liquid flow through the second flow channel. The first and second bi-stable latching valve each comprise a piezoelectric actuator for selectively opening and blocking the flow channel, and a magnetic latch for locking the valve in a closed position.
BRIEF DESCRIPTION OF THE FIGURES
[0012] [0012]FIG. 1 is a cross-sectional side view of an embodiment of the bi-stable latching valve of the present invention.
[0013] [0013]FIG. 2 a is a detailed side view of the bi-stable latching valve of FIG. 1 in an open position.
[0014] [0014]FIG. 2 b is a top view of the bi-stable latching valve of FIG. 2 a.
[0015] [0015]FIGS. 3 a and 3 b illustrate the bi-stable latching valve switching from a closed position to an open position.
[0016] [0016]FIGS. 4 a and 4 b illustrate the bi-stable latching valve switching from an open position to a closed position.
[0017] [0017]FIG. 5 is a schematic diagram of a flow regulating system for a microfluidic system implementing a plurality of bi-stable latching valves according to an illustrative embodiment of the invention to provide variable control of fluid flow.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention provides a digital latching micro-regulator including a bi-stable latching valve for accurately controlling fluid flow on demand. The present invention will be described below relative to an illustrative embodiment. Those skilled in the art will appreciate that the present invention may be implemented in a number of different applications and embodiments and is not specifically limited in its application to the particular embodiments depicted herein.
[0019] The present invention provides a bi-stable latching valve for selectively blocking fluid flow through a channel. The valve is positioned in a channel to selectively block liquid flow through the channel. As shown in FIG. 1, the bi-stable latching valve 10 of the present invention comprises a substrate 20 having an inlet port 22 and an outlet port 24 formed therein in fluid communication with a channel through which liquid flows. The substrate 20 is preferably formed of glass or plastic, though other materials may be used. The bi-stable latching valve 10 further includes a valve seat 30 cooperating with the substrate to define a valve chamber 26 in communication with the inlet port 22 and the outlet port 24 for containing a volume of fluid. The valve seat 30 selectively blocks the inlet port 22 to regulate the flow of fluid into the chamber 26 . The position of the valve seat 30 controls the fluid flow into the chamber 26 . The position of the valve seat 30 is controlled by an actuator assembly 50 . The actuator assembly can comprise any suitable structure for selectively operating or moving the valve seat 30 to block the inlet port 22 or the outlet port 24 . According to one embodiment, the actuator assembly includes a cantilever beam 40 hinged to the substrate 20 , an actuator 52 , and a latching mechanism 60 .
[0020] The position of the valve seat 30 is determined by the position of the cantilever beam 40 . The valve seat 30 is connected to the cantilever beam 40 , which is in turn connected to the actuator 52 . The actuator 52 can comprise any suitable structure for moving the valve seat 30 between an open position for allowing fluid to enter or exit the chamber, and a closed position. Examples of suitable actuators include mechanical, electrical, electromechanical, and magnetic devices. According to a preferred embodiment, the actuator 52 is a piezoelectric element. The cantilever beam 40 is hinged at a first end 41 to the glass substrate 20 and rotates about the fixed hinge under the control of the actuator 52 to move the valve seat 30 between the open and closed positions. When the cantilever beam 40 is lowered, the beam pushes the valve seat 30 into a closed position, thereby blocking the inlet port and preventing fluid flow into the chamber. When the cantilever beam 40 is raised, the valve 30 is moved to an open position to allow fluid flow through the chamber 26 . The cantilever beam 40 is driven by the piezoelectric element 52 , which selectively applies a driving force to the beam 40 .
[0021] The bi-stable latching valve 10 further includes a latching mechanism 60 for selectively latching or holding the beam 40 in a selected position. The latching mechanism can include any suitable mechanical, electrical, electromechanical or magnetic structure suitable for latching the beam 40 . The latching mechanism 60 , according to a preferred embodiment, comprises a permanent magnet 62 and a permalloy element 46 disposed on a free end 44 of the beam 40 . The permanent magnet 62 is attached to the glass substrate 20 opposite the permalloy element 46 and is configured to attract the permalloy element 46 . The magnetic attraction between the permanent magnet and the permalloy element is effective to latch, i.e. to retain, the valve element in a closed position to prevent fluid flow through the bistable latching valve 10 .
[0022] As shown in FIGS. 2 a and 2 b , the valve seat 30 is cylindrical in shape and includes a rim 38 about the circumference of the valve seat 30 , which defines the valve chamber 26 . The rim 38 cooperates with the glass substrate 20 to fluidly seal the valve chamber 26 . The valve chamber communicates with the inlet port 22 and the outlet port 24 . The valve seat 30 is preferably formed of a flexible material, such as silicone rubber, though one skilled the art will recognize that alternate materials may be used. The valve seat 30 further comprises a membrane portion 32 , a first protrusion 34 for contacting the cantilever beam 40 and second protrusion 36 for selectively blocking the inlet port 22 to prevent the flow of fluid through the valve chamber 26 , thereby blocking fluid flow through the associated channel. The second protrusion blocks the inlet port 22 when the cantilever beam depresses the valve seat 30 by pushing on the first protrusion 34 . One skilled in the art will recognize that the valve seat 30 is not limited to a cylindrical shape, and that any suitable shape may be utilized.
[0023] The operation of the bi-stable latching valve 10 is illustrated in FIGS. 3 a - 3 b and FIGS. 4 a - 4 b . The bi-stable latching valve 10 switches between two stable states: an ON state, which allows the flow of liquid through the valve chamber and an OFF state, which prevents the flow of liquid through the valve chamber. The state of the bi-stable latching valve 10 is controlled by the driving force on the cantilever beam 40 by the actuator 52 and the magnetic latching force created by the permanent magnet 62 on the beam free end. According to the illustrative embodiment, the bi-stable latching valve only requires power to switch between the two stable states and does not otherwise require power to operate.
[0024] [0024]FIG. 3 a illustrates the bi-stable latching valve 10 in an OFF state, where the second protrusion 36 of the valve seat 30 blocks the inlet port 22 so that fluid is prevented from flowing through the valve chamber 26 . In the OFF state, the latching mechanism 60 latches the cantilever beam 40 in the closed position by securing the permalloy element 46 to the permanent magnet 60 . As shown, when the attractive force of the magnet pulls the cantilever beam towards the magnet, causing the cantilever beam to push the valve into the closed position, such that the first protrusion blocks the inlet port. The valve maintains the closed position until activated.
[0025] To open the bi-stable latching valve and allow fluid flow, a voltage is applied to the piezoelectric element 52 using a controller (not shown). The applied voltage causes the piezoelectric element to compress, applying an opposite force on the cantilever beam in the direction away from the magnet. If the force generated is sufficient to overcome the magnetic attraction between the magnet and the permalloy, the magnet releases the permalloy element and the cantilever beam raises, pulling the valve seat 30 clear of the inlet port 22 . As shown in FIG. 3 b , fluid flows through unobstructed inlet port 22 into the valve chamber and out of the valve chamber via the outlet port.
[0026] The bi-stable latching valve 10 remains in the ON state, as shown in FIG. 4 a , until the controller subsequently actuates the piezoelectric element 52 by applying a second voltage. The second voltage causes the piezoelectric element to expand, which applies a driving force on the cantilever beam 40 , pushing the beam towards the magnet 60 . The lowered beam in turn applies a force to the valve seat 30 , which shifts into a closed position, blocking the inlet port. When the permalloy element 46 is brought close to the magnet 62 , a magnetic latching force generated by the magnet latches the beam 40 into the closed position until a subsequent actuation of the piezoelectric element 52 .
[0027] The bi-stable latching valve 10 may be employed in a valve architecture to provide binary addressable flow control using digital latching. As shown in FIG. 5, multiple bistable latching valves may be connected to channels 550 of specific flow conductance that vary according to a pre-determined ratio to provide a micro-regulator 500 . Each bi-stable latching valve 10 can be set to an on or off state as described previously, allowing or blocking flow through its associated flow channel 550 . The bi-stable latching valves are selectively activated in various combinations to provide a number of discrete flow conductance states through the micro-regulator 500 . The net flow through the micro-regulator is therefore determined by the sum of the flows through the open bi-stable latching valves 10 . The number of discrete flow conductance states is determined by the number of bi-stable latching valves in the system and the flow conductance ratios between the channels.
[0028] A typical example of a 4-bit micro-regulator system is illustrated in FIG. 5. The individual channels 550 a , 550 b , 550 c and 550 d in the system have flow conductance ratios of 1:2:4:8, thus providing 16 discrete net flow conductance states. For example, a first flow conductance state may be provided by opening all of the bi-stable latching valves 10 a - 10 d to allow flow through all of the channels 550 a , 550 b , 550 c and 550 d . A second flow conductance state is achieved by closing the first bi-stable latching valve 10 a , while leaving the remaining bi-stable latching valves 10 b , 10 c , 10 d open, allowing fluid flow through the channels 550 b , 550 c and 550 d only. A third conductance state is achieved by closing the first and second bi-stable latching valves 10 a , 10 b while leaving the remaining bi-stable latching valves 10 c , 10 d to allow flow through the associated channels 550 c and 550 d , and so on. This allows flow rates to be controlled to a 6.67% precision. Higher precision can be obtained by increasing the number of bits in the system—for example an 8-bit system has 128 discrete states, achieving less than 1% precision in the flow rate control.
[0029] One skilled in the art will recognize that any suitable bi-stable valve for selectively blocking liquid flow through a channel may be used in the flow regulating system 500 of FIG. 5 to provide variable flow resistance. The micro-regulator 500 may have any suitable number of channels arranged in any suitable configuration and having any suitable flow resistance to achieve a system having variable flow resistance, wherein the flow resistance depends on the state of the bi-stable valves.
[0030] The manufacturing process for the bi-stable latching valve 10 of an illustrative embodiment of the present invention is efficient, economical and simplified. The valve seat 30 may be formed by surface micromachining of a substrate, followed by deposition of silicone rubber, the permalloy element 46 and polysilicon. The substrate 20 is etched to form a channel and then drilled to form the inlet port 22 and the outlet port 24 . The cantilever beam 40 may be attached and hinged to the glass substrate through means known in the art. The permalloy element may be bonded to the beam and the permanent magnet 62 may be bonded to the substrate through means known in the art. The piezoelectric element 52 or other actuator for driving the cantilever beam 40 may be attached to the beam through any suitable means.
[0031] The present invention has been described relative to an illustrative embodiment. Since certain changes may be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense.
[0032] It is also to be understood that the following claims are to cover all generic and specific features of the invention described herein, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. | 4y
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RELATED APPLICATIONS
This is a continuation-in-part of our application Ser. No. 347,967, filed Apr. 4, 1973, now abandoned.
FIELD OF THE INVENTION
This invention relates to the inhibition of the troublesomely accelerated decomposition or rapid burning of an aqueous solution of an organic oxidant such as an organic hydroperoxide.
PRIOR ART
Heretofore the hazards of very rapid decomposition or combustion of organic oxidant materials has been sufficiently recognized that safety engineers have generally packaged such compositions in relatively small containers, such containers usually being polyethylene bottles. An aqueous solution containg about 30 percent by weight water and about 70 percent by weight of TBHP (tertiary butyl hydroperoxide) is a versatile material which has been used as a catalyst for various systems and which has also been used as an oxidant. Initially, customers were satisfied with shipment of TBHP-70 in pint bottles or other small containers. For a number of years, there has been a demand for shipment of 70 percent aqueous TBHP as a bulk shipment in tank cars. Being an organic oxidant, no bulk shipment could be made unless the freedom from hazards of troublesomely rapid decomposition or combustion was adequately established by appropriate proof. The knowledge that other peroxide compositions were dangerous under conflagration conditions was not only sufficient to restrict the packaging of 70 percent aqueous TBHP to small containers but also sufficient to guide interested parties to accept as permanent the classification of the significant hazards of the material.
Heretofore various oxidants have been shipped in combination with inhibitors adapted to minimize the danger of very rapid burning or decomposition, such hazard reductants being of the non-flammable, flame retardancy type adapted to retard the oxidizing propensities of the organic oxidant. Non-combustible solvents have also sometimes been employed to bring about the distribution of the organic oxidants throughout a sufficiently enlarged zone to inhibit unduly rapid decomposition or burning during any accident. Notwithstanding the abundance of research on fire retardants and the demand for better shipping containers for 70 percent aqueous TBHP, no satisfactory answer to the long-standing problem was developed.
Radical traps have heretofore been employed in inhibiting polymerization of monomers and in imparting a useful degree of resistance to sunlight in organic plastics.
SUMMARY OF THE INVENTION
In accordance with the present invention, the combustion hazards of an aqueous solution containing about 70 percent by weight TBHP (that is, tertiary butyl hydroperoxide) are significantly reduced by the use of a radical trap in a concentration from about 10 to about 100,000 parts of radical trap per million parts of TBHP, such radical trap being protected from pre-combustion inactivation by incorporation in a polyolefin. Examples of suitable radical traps include:
alkyl phenols
phenothiazines
substituted naphthyl amines
phenylene diamines
dibenzylamine
iminodibenzyl
Other radical traps having effectiveness in inhibiting sunlight damage, polymerization, etc. are effective but outside the desired group of compounds.
The present invention also features a system comprising the combination of an aqueous solution containing about 70 percent by weight TBHP (that is, tertiary butyl hydroperoxide) and a hazard reducing quantity of a polyolefin having a melt index from about 0.2 to about 10. Such can be employed as a system inhibited to resist troublesomely rapid combustion (sometimes conventiently designated as rapid decomposition). In the event that such composition accidentally burns, it can burn to extinction without troublesomely rapid decomposition or combustion. Polyolefins are combustible, and it is surprising that the addition of such combustible component should function as a hazard reductant effectivee enough to overcome obstacles to bulk shipments of 70 percent TBHP. If the polyolefin is employed as a liner, its thickness should be within a range from 0.7 to 7 mm, or about 1/64 to about 1/4 inch. If particles of polyolefin are employed, they should constitute about 0.6 to 6 percent by weight of the composition.
DESCRIPTION OF PREFERRED EMBODIMENTS
The nature of the invention is further clarified by reference to a plurality of examples.
EXAMPLE 1
In a control test, a five-gallon steel pail was filled with about 4.5 gallons of aqueous TBHP-70 (tertiary butyl hydroperoxide containing 30 percent water) and placed on two 8-inch high cinderblocks for a combustion test. A lid having 4 holes of about 1/4inch diameter was loosely positioned on top of the pail. Kindling wood, soaked with kerosene was placed beneath and around the pail, so that in the combustion, the flames approached several surfaces of the shipping pail. After the kindling had been ignited, the TBHP-70 took fire and the contents of the pail burned with moderate intensity. The combustion of the aqueous TBHP-70 appeared to advance satisfactory for about 20 minutes. However, just prior to the end of the burning of the aqueous TBHP-70, there was an accelerated decomposition (conveniently designated as a very rapid combustion) whereby the bottomm and sides of the pail were distorted, the lid was expelled from the pail, the fire was extinguished, and a muffled noise was heard. This type of rapid decomposition or burning near the end of the combustion of an organic oxidant is a type of hazard which had previously been observed for and was generally expected from concentrated aqueous solutions of organic oxidants. The restrictions which safety experts have imposed upon the transportation and storage of organic oxidant materials are attributable to such propensities toward troublesomely rapid decomposition or combustion.
In an example of the invention, several pieces of polyethylene, shaped as curved saddles and designed as contact surfaces in solvent extraction or distillation apparatus and having dimensions of about 3 inches long and about 1.8 inches wide were employed and floated on or near the top of surface of the TBHP-70. The saddles had a surface area of 227 square inches. The weight ratio of the polyethylene to the aqueous TBHP-70 was 0.0123 to 1; that is, the polyethylene constituted about 1.23 percent by weight of the TBHP-70. When the combination of the 4.5 gallons of aqueous TBHP-70 and 1.23 percent polyethylene was subjected to the standard combustion test using kerosene soaked kindling wood to heat the pail supported on 8-inch blocks, the material in the pail burned. There was no audible or visual indication of troublesomely rapid decomposition or combustion. Thus, it differed from the control in that the lid was not ejected and the sides of the pail were not distorted. The terminal portion of the burning of the organic oxidant was acceptable to safety standards because the presence of the polyethylene components so modified the total combustion that it could proceed smoothly until all of the combustible matter was consumed.
In another control, the 4.5 gallons of aqueous TBHP-70 were modified by the use of polyethylene saddles constituting 0.5 weight percent of the TBHP-70 and the standard combustion test was conducted. The TBHP burned for about 24 minutes at about which time the cover was blown from the pail by the intensity of the terminal stages of the combustion but there was no conspicuously loud explosive noise.
By a series of tests, it is established that when the polyethylene is in the form of particles, the concentration of the polyethylene should be at least 0.6 weight percent of the TBHP-70 and that little safety advantage is achieved by the use of more than 6.0 weight percent of the polyolefin. Such weight concentration limits are not relevant to lined containers, in which the thickness of the lining is the significant safety feature.
EXAMPLE 2
Polypropylene saddles, each saddle having a dimension of about 2 inches and marketed by the Norton Company as an "Intalox" brand of saddle are sometimes employed as packing in a distillation column. The addition of 30 saddles to 4.5 gallons of TBHP-70 represented about 1.8 percent by weight of the aqueous organic oxidant. In the standard combusion test, such proportions of polypropylene saddles are effective in maintaining the generally normal combustion of the organic material in the pail until all of such organic material was burned, thus avoiding the propensities of the unmodified TBHP to burn with troublesome rapidity.
Example 3
A 5-gallon steel pail was modified by bonding a polyethylene liner thereto, the liner constituting 5.58 percent by weight of the 37 pounds (approximately 4.5 gallons) of TBHP-70. The combination was subjected to the previously described standard combustion test. Containers of organic oxidants must pass such standard test to meet the safety standards appropriate for transportation of merchandise. The contents of the polyethylene-lined pail burned for about 29 minutes with smooth combustion until the TBHP was completely burned in about 29 minutes. The lid was not ejected nor was there other evidence of troublesomely rapid decomposition or combustion. The polyethylene liner does effectively inhibit the propensities of the TBHP.
By a series of tests, it is established that the thickness of a polyolefin (e.g., polyethylene, polypropylene, etc.) liner should be from about 0.7 to about 7 mm. (about 1/64 to about 1/4 inch) and that the melt index of the polyolefin must be within the range from 0.2 to 10 as measured by ASTM 1238 Condition E procedure. It is important that the polyolefin be free from metallic contaminanta (e.g., residues from catalysts) scrap, and/or pigments which might alter its modifying role.
In a control procedure a sample of polyethylene having a melt index of 0.1 (that is, half of the minimum requirement of the present invention) is subjected to a molding operation in an effort to provide a liner for a five-gallon bucket. Difficulties are encountered in the adhesion of the liner in the molding and in the cooling of the molded liner from molding temperature. The thus defined pail is subjected to the standard combustion test, during which the lid is expelled and a noise is heard indicative of troublesomely rapid combustion. Such adverse result is possibly attributable to a propensity of the difficulty meltable polyethylene to burn only at the interface of liquid and air instead of predominantly melting before combustion.
In a control procedure, a sample of polypropylene having a melt index of 15 is employed in the form of short hollow tubes (such as is used as packing in liquid vapor contact towers) dispersed in aqueous 70 percent tertiary butyl hydroperoxide, the polypropylene constituting 0.7 percent by weight of the composition. In the combustion test, the lid is expelled and a noise indicates troublesomely rapid decomposition or burning. The polypropylene has a sufficiently low melting point that substantially all of the polypropylene is melted and burned during the early portions of the test, leaving no polypropylene for modifying the terminal phases of the combustion.
By a series of tests, it is established that the melt index for the polyolefin must be within a range from 0.2 to 10.
Example 4
In a control, a 55-gallon steel drum filled with 70 percent aqueous TBHP was subjected to the standard combustion test, and the steel drum was destroyed by the rapidity of the terminal stages of the burning.
A commercially available drum having a polyethylene liner was employed in the same test and shown to be a safe container. The flames continued for 50 minutes without troublesomely rapid burning. The 2SL polyethylene liner had a melt index of 2.6 and a density within a range from 0.910 to 0.925 and was about 3/16 inch thick.
As an example of the present invention, a semitrailer having a 2000 gallon steel tank is lined with polyethylene having a thickness of 5 mm., a density of about 0.92, and a melt index of about 2.0. The tank is partially filled with TBHP-70 and ignited. The combustion advances smoothly, and the composition burns without troublesomely rapid decomposition or combustion, by reason of the presence of the polyethylene liner in the tank.
With the aid of retrospect, it is believed that the combustion of the polyethylene or other thermoplastic polyolefin is initiated and advances concurrently with the combustion of the TBHP and that during the final stages of the combustion, when the oxidant concentration is high and the temperature is high, tending to promote troublesomely rapid decomposition or combustion, the combustion of the plastic consumes the oxidant at a rate sufficient to avoid the developement of such troublesomely rapid burning rates.
EXAMPLE 5
2-methyl,4,6-di-tertiarybutyl phenol (conveniently abbreviated as MDTBP) is a useful inhibitor for reducing the rate of reactions involving a free radical mechansim. Discoloration of organic liquids exposed to sunlight, polymerization of monomers, and thermal activation of hexaarylyl plumbanes are inhibited by MDTBP. Particles of MDTBP are encapsulated in polypropylene to provide a flowable powder of spheroids functioning as a microencapsulated form of MDTBP, the polypropylene skin constituting about 25 percent of the weight of each spheroid. In a series of tests, in each of which a bucket containing about 35 pounds of TBHP is modified by the addition of a controlled amount of spheroids of encapsulated MDTBP and subjected to the standard combustion test, it is shown that the concentration of MDTPBP desirably should be between about 10 and about 100,000 parts of MDTPB per 1,000,000 parts of aqueous TBHP. Concentrations greater than 10 ppm but less than 10,000 ppm are preferred.
By using 1,000 ppm, the microencapsulated phenol achieves a sufficiently reliable reduction of hazard during combustion to offer an attractive combination of advantages. The microencapsulated phenol is more costly per pound than polyolefin, but by using a smaller concentration of microencapsulated phenol, adequate reduction of hazard is attainable at a competitive price. For shipments involving costly freight costs and involving single usage of the modifier, encapsulated phenol spheroids offer an economic advantage even when more costly when comparing merely the expense of formulation.
In a series of tests of microencapsulated radical traps, it is shown that 1,000 parts of radical trap per 1,000,000 parts of aqueous TBHP, it is shown that phenothiazines such as 4,6 dimethylphenothiazine, substituted naphthyl amines such as 3-4 dimethylalphanaphthyl amine, phenylenediamines such as 2,4 diaminotoluene, dibenzyl amines such as bis(s-ClC 6 H 4 CH 2 ) 2 NH, and iminodibenzyls such as p Me 2 Nc 6 H 4 C 2 H 4 C 6 H 4 NMe 2 , are effective agents for reducing the hazard in combustion of TBHP.
Another phenol found to be satisfactory is DTBMP or 2,6,di-t-butyl,-4-methyl phenol. The trademark "IONOL" identifies one brand of such DTBMB.
Polyolefin manufacturers regularly employ controlled amounts of radical traps in all molded products. For example, some polyethylene saddles contain about 0.25 weight percent of IONOL brand of DTBMP (2,6 di-t-butyl-4-methyl phenol). Low density polyethylene having a melt index of 1.1 and containing about 0.25 weight percent IONOL brand of DTBMP is manufactured as a flexible sheet about 4 mm. thick. The sheet is cut to provide about 194 g. of polyethylene as 18 rectangular ribbons about 51 mm. by 25 mm. These ribbons are employed in the 35 pound of aqueous TBHP in the standard combustion test and found to be effective in preventing an excessive rate of terminal decomposition. Such test established the usefulness of 35 ppm of IONOL as a combustion modification agent.
EXAMPLE 6
Low density polyethylene having a melt index of 2.1 and containing 0.15 percent IONOL was fabricated into saddles suitable as packing for treatment towers. Six saddles (188 g.) were employed in the standard combustion test. The concentration of IONOL in aqueous TBHP was about 18 ppm and was sufficient to avoid the troublesomely excessive decomposition.
The need for the modification of the decomposition is only for the final minutes of the burning, and whatever modifier is employed must be preserved in a form having appropriate effectiveness after most of the TBHP has burned. The polyolefin might be interpreted as the significant modifier. The radical trap might be interpreted as the significant modifier. Regardless of theoretical interpretations of the results, the facts show that troubles are avoided by the use of polyolefin containing radical trap materials, thus providing a basis for claiming the process featuring the polyolefin as well as the process featuring the radical trap.
Various modifications of the invention are possible without departing from the scope of the appended claims. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to sawmill equipment, and more particularly to an apparatus and method for positioning boards to be fed through board edging saws to expose maximum usable dimensioned lumber therefrom. In greater particularity, the present invention relates to an infeed table system for a board edge trimming device.
2. DESCRIPTION OF THE PRIOR ART
The boards handled by the infeed table are sawn cants. Cants are commonly described as planks of portions of logs after longitudinal ripsawing. They generally have flat top and bottom horizontal surfaces and unfinished and irregular longitudinal sides surfaces, called wane edges, which may still have bark. To produce dimensioned lumber, wane edges require to be eliminated. Conventionally an edging saw assembly will comprise at least two circular saws removing the wane edges of the board.
Numerous computer controlled systems have been developed to optimize the trimming of wane edges of boards to produce dimensioned lumber while minimizing waste. Optimization is obtained, for example, by using optical scanners which relay data on the specific morphology of a board to a computer which receives and analyses the data to control the board edge trimming process. The optical scanning method consists of transversely moving a board across light beams located at various points along the length of the board such that the light beam is interrupted and the restored as the board passes. The resultant measurement data is then fed to a computer which will compute a prescribed edging cut to maximize the production of useful dimensioned lumber. The computer will then control equipment which will effect such a preferred cut. Various examples of such systems are disclosed in the Sanglert U.S. Pat. No. 3,963,938 issued Jun. 15, 1976, in the Berry U.S. Pat. No. 4,086,496 issued Apr. 25, 1978, in the McGeehee U.S. Pat. No. 4,468,992 issued Sep. 4, 1984, and in the Wadell U.S. Pat. No. 4,471,823 issued Sep. 18, 1984.
With optical scanning systems, optimization of the edge trimming process is achieved in either of two ways. According to a first method, the edge trimming saws can be laterally adjustable relative to a constant edging path followed by every board as shown for example, by Sanglert U.S. Pat. No. 3,886,372. However, such methods require the replacement, at a great expense, of existing non-laterally adjustable board edging saw equipment with new computer controlled laterally adjustable board edging equipment. Consequently, such methods have failed to gain recognition and have failed in replacing conventional equipment.
In another method, optimization is achieved with conventional fixed position edge saws but the boards are precisely aligned on an preferred edging path determined by the computer based on the optical scanning data. This permits computer controlled cutting optimization systems to be used with existing fixed position board edging equipment (Horn et al U.S. Pat. No. 4,240,477). More particularly, Horn et al disclose a computer controlled alignment system using a movable mounting frame. Boards are laid on the mounting frame which is displaced, transversely to the edging path, to a final position which is computed to align the board with a preferred edging path and allow the board to be propelled by spiked feed rollers along the preferred edging path. The mounting frame slides on ball bearings on beams which are themselves bolted to the floor of the mill. Such systems have the inherent and severe drawback that they fail to be operable at the high processing speeds required in modern and efficient milling operations. To be more explicit, in the system disclosed by Horn et al, the mounting frame is moved by hydraulic cylinders. In addition, shock dampers are provided at each extremity of the range of movement of the mounting frame. In use, the mounting frame will slam against the hydraulic shock dampers and the momentum carried by the mounting frame will be transmitted to the support structure holding the hydraulic shock dampers and finally to the mill floor. If the system is accelerated, the slamming effect will in all probability increase to a point where the lumber resting on the mounting frame will skid on it and lose its alignment along the preferred edging path. This is especially true when slippery wet or frozen boards are being processed. More importantly, the entire assembly will become subjected to important structural shocks and will be prone to breakdowns.
Thus the need exists for board infeed optimization equipment which can smoothly and quickly position a board along a preferred edging path while being operable in conjunction with a conventional optical scanning system and conventional fixed woodworking equipment such as a fixed position edging device.
SUMMARY OF THE INVENTION
It is, therefore, an object of this invention to provide a board infeed optimization system capable of smoothly and quickly moving boards transversely to a position aligned with a preferred edging path to permit a conventional optical scanning system and a computer controller to be used with conventional fixed edging equipment.
It is a further object of this invention to provide a board infeed optimization system which can be used with an optical scanning device and a computer controller to select one from a plurality of preferred edging paths leading to different fixed edging devices and capable of smoothly and quickly positioning the boards along this most preferred edging path.
It is still a further object of this invention to provide a computer controlled board infeed optimization system which prevents boards from slipping, bouncing, or sliding during their positioning in alignment with a preferred edging path.
In accordance with these and other objects of the invention, a board edging infeed optimization system is capable of positioning an elongate cant, in an infeed line of direction generally parallel to its elongate axis, to an edging device capable of cutting the cant along parallel, spaced-apart cutting lines, to remove the wane edges thereof, the apparatus comprises:
conveying means for conveying the cant in a direction transverse to its elongate axis and along a substantially straight path;
scanning means located along the path for optically scanning the morphology of the cant, linked to a computer for analyzing the morphology data and determining a preferred infeed line of direction into said edging device;
positioning means located further along the path for positioning the cant in a direction transverse to its elongate axis and at a location remote from the preferred infeed line of direction;
means coupled to rotatable eccentric arm means and capable of seizing the cant, displacing the cant further along the path and positioning and releasing the cant in a direction transverse to its elongate axis and colinear with the preferred infeed line of direction;
feeding means for advancing the cant, in a direction colinear with the preferred infeed line of direction and into said edging device;
According to a preferred embodiment, the apparatus comprises a conventional optical scanning station; a computer controller which will analyze data from the optical scanning station and place movable positioning pegs at a set distance from preferred edging paths for the board; a mechanism providing transverse advancement of the bord along the path culminating in a rest position in abutment with positioning pegs; a grip roller assembly adapted to clamp a board; an eccentric arm system linked to the grip roller assembly and capable of displacing it together with a clamped board therein, by a further set lateral distance along the path, of the thereby positioning the board in longitudinal alignment with its preferred infeed line; and a further grip roller assembly adapted to longitudinally thrust the board into the edging device.
If required, friction shoes may be installed directly above the general location of the positioning pegs to ensure that the advancing boards will sequentially come to rest in abutment with the positioning pegs and will not bounce or slide out of position.
According to a possible embodiment of the invention, the eccentric arm and the advancement system are activated by a motors through chain drives.
According to a possible embodiment of the invention, the positioning pegs are displaced by two arms linked to two computer controlled linear positioning hydraulic cylinder systems.
Also according to a possible embodiment, the eccentric arm assembly may be adjustable to permit to selectively feed boards into a plurality of adjacent edging devices.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that this detailed description, while indicating preferred embodiments of the invention, is given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the board edging infeed optimization system in accordance with the present invention which comprises apparatus to transport boards trough a scanning station and further transport the boards to reach longitudinal alignment with a preferred board edging path;
FIG. 2 is a plan view of a cant, i.e. a board with rough side edges, with projected edge trimming cut lines as determined by the optimization system in accordance with the present invention;
FIG. 3 is a fragmentary perspective view of an hydraulic linear positioning cylinder assembly comprising an positioning stop which is positioned at a set distance away from a preferred board edging path;
FIG. 4 is a top view of the board edging infeed optimization system in accordance with the present invention and adapted to feed boards to a fixed position edging saw assembly;
FIG. 5 is a fragmentary vertical front elevational view of the machine shown in FIGS. 1 and 4, taken generally along line 5--5 on FIG. 4;
FIG. 6 is a fragmentary vertical side elevational view of the machine shown in FIGS. 1 and 4, taken generally along line 6--6 on FIG. 8 and schematically showing the transverse transport mechanism of the boards through the optical scanning station on their route to the positioning pegs and schematically showing top friction shoes to prevent the boards from bouncing or sliding out of alignment.
FIG. 7 is a fragmentary perspective view of the eccentric arm mechanism effecting transverse transport of the boards to position the boards in alignment with their preferred edging paths in accordance with the present invention;
FIG. 8 is a perspective view showing the board edging infeed optimization system in accordance with the present invention which embodies top friction shoes.
FIG. 9 is a top view of an alternate embodiment of a board edging infeed optimization system in accordance with the present invention and adapted to selectively feed boards to either of two fixed position edging saw assemblies;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 of the drawings, an infeed optimization system 10 is shown for feeding boards through longitudinal edge trimming saws (not shown) called edgers. The aim of the system 10 is to automatically select a preferred feeding path, smoothly and rapidly transport the boards to a position in alignment with the preferred feeding path and to propel the boards through the edger in order to expose the optimum amount of useful dimensioned lumber. A board 12 will enter the infeed system 10 transversely in the general direction indicated by arrow 1. The infeed system 10 will continue to displace the board 12 transversely until the board 12 reaches alignment with its preferred longitudinal feeding path in the general direction indicated by arrow 2 to enter an edger unit (not shown).
Turning now to FIG. 2, the boards 12 handled by the system 10 are cants having wane edges 14 which may still exhibit bark. These wane edges 14 require to be eliminated to obtain useful dimensioned lumber. The dotted lines shown on board 12 are representative of the preferred trimming lines as calculated by a computer (not shown) from optical data provided by an optical scanning station 16 as shown in FIG. 1. The edger unit (not shown) is conventional and comprises non-laterally displaceable saws. Thus, to optimize the edge trimming process, the feeding path of the board 12 through the edger unit (not shown) is the only variable to be adjusted to allow optimization of the wane edge 14 removal.
Referring again to FIG. 1 of the drawings, a board 12 enters the system 10 on transverse transport endless chains 18 and 20 located below and generally under the longitudinal end portions of board 12. The board 12 is pushed forward transversely by pushing lugs 22 and 24 projecting upwardly at regular intervals on endless chains 18 and 20, respectively. In this way a board 12 will transversely travel through the optical scanning station 16 located above and below the board 12. Transverse transport endless chains 18 and 20 are supported and advanced in unison by pairs of co-axial sprocket wheels (typically shown in FIG. 6 at 17) and mounted on common axles (typically shown in FIG. 1 at 19). The assembly of sprocket wheels 17 is motorized by torque axle 19 which is driven by a suitable electric motor (not shown).
The optical scanning station 16 may be of conventional commercially available manufacture such as an Autolog® scanning station. The optical scanning station will measure the specific morphology of board 12. The morphology data provided by the optical scanning station 16 is relayed to a computer (not shown) by appropriate transducers (not shown) and wires (not shown). The computer will then calculate the best manner to further process a board 12 in order to remove its wane edges 14. More particularly, the computer will calculate the location of a preferred longitudinal feeding path to the edger unit (not shown) corresponding to an optimum trimming and removal of the wanes edges 14 on each board 12. The computer will consequently calculate the amount of further transverse transport each board 12 will require for it to reach longitudinal alignment with its preferred feeding path. The equipment of infeed system 10 is designed to transversely transport a board 12 in two distinct steps. In the first step board 12 will be transversely displaced by a variable distance X. In the second step board 12 will be further transversely displaced by a constant distance C. This two step operation is calculated to provide enough transverse movement of board 12 for it to reach longitudinal alignment with its preferred feeding path as calculated by the computer (not shown). The overall transverse movement can easily be summarized by the following formula:
X+C=PFA
where
X=variable transverse distance
C=constant transverse distance
PFA=preferred feeding alignment into edger unit first travel a variable transverse distance and then travel a further constant transverse distance.
To effect the required variable distance X of transverse transport of board 12, the computer will control and position linearly displaceable positioning pegs 26 and 28. Board 12 will transversely advance on endless transverse transport chains 18 and 20 and will be gradually be transferred onto parallel endless transverse transport chains 32 and 34 to reach abutment on positioning pegs 26 and 28. Transport chains 32 and 34 are supported and advanced in unison by pairs of co-axial sprocket wheels (typically shown in FIG. 6 at 31) mounted on common axles (typically shown in FIG. 1 at 33). The assembly of sprocket wheels 31 is motorized by torque axle 33 which is driven by a suitable electric motor (not shown).
It is to be understood that transport chains 18, 20, 32, and 34 are driven in unison at a chosen linear velocity to transversely advance board 12. The linear velocity in calculated by the computer (not shown) so that the overall infeed system 10 can operate at a chosen pace.
To effect the required further constant distance C of transverse transport of board 12, the computer will automatically direct equipment to seize board 12, transversely transport it by the constant distance C and lower board 12 onto appropriately spiked feed rollers which will propel board 12 into the edger unit (not shown) that is in the general direction indicated by arrow 2 in FIG. 1.
The movement of board 12 through infeed system 10 will now be tracked and described in further detail. Similarly the equipment comprised in infeed system 10 will also be described in more detail.
Once a board 12 has been scanned as described above, the board 12 will enter the infeed station 30 while transversely displaced by riding on the pair of endless transport chains 18 and 20. In entering infeed station 30 the board 12 is transferred onto and continues to advance on a second pair of endless transverse transport chains 32 and 34 until it reaches a position of abutment on positioning pegs 26 and 28. Positioning pegs 26 and 28 are vertically and fixedly inserted on linearly movable beams 36 and 38, respectively. Referring now to FIG. 3, the linear positioning of each of movable beams 36 and 38 is under the control of the computer (not shown) and is effected by an hydraulic servo linear positioner cylinder 40 (shown in FIG. 3) of commercially available manufacture such as a LinearLogic® servo positioner cylinder. Each of movable beams 36 and 38 is linked to the push rod 42 of a servo linear positioner cylinder 40 by a suitable connection 44 and will easily slide in support rings 46 conveniently lubricated and placed at regular intervals along the length of beams 36 and 38.
Board 12 having then travelled the computed variable transverse distance X specific to its morphology, board 12 will then be seized by clamping means and further displaced transversely by the constant transverse distance C. The resulting position of board 12 will then be in alignment with its preferred feeding path.
This invention is, among other characteristics, particularly concerned with the further transverse movement corresponding to transverse distance C., that is in the general direction indicated by arrow 1 in FIG. 1 and generally transverse to the infeed direction into the edger unit (not shown) in the general direction indicated by arrow 2 in FIG. 1. This operation is effected, in general terms, by seizing board 12 with a pair of slidable clamping assemblies (typically shown at 48) in FIG. 7 and sliding the clamping assemblies 48 along the transverse distance C and subsequently releasing board 12 in a position of longitudinal alignment with its preferred feeding path. This operation, to be profitable, requires to be effected precisely, quickly and smoothly to allow the infeed system 10 to operate at a high production rate. Still referring to FIG. 7, it has been discovered that by using a pair of eccentric arm assemblies (typically shown at 50) of the present invention, it is possible to reach these objectives. An eccentric arm assembly 50 incorporates the important benefit of being able to cause a smooth and rapid longitudinal back and forth sliding movement of a clamping assembly 48 while minimizing structural stresses on the infeed system 10 during acceleration and deceleration of said clamping assembly 48.
Referring now to FIGS. 4 and 5, clamping assembly 48 comprises a pair of top and bottom parallel shafts 52 and 54 located just above and below the plane of movement of board 12 and on each of which is fixedly a mounted a support bracket 56 holding a rotatable spiked roller 58. Both top and bottom shafts are rotatably mounted at their back longitudinal ends on rear bracket 60 so as to be longitudinally movable, in unison, when rear bracket 60 is moved by the eccentric arm assembly 50. Bottom shaft 54 is longitudinally slidable on bottom support sleeves (typically at 62) fixedly mounted on support beam (typically at 64 and shown in dotted lines) 64. Top shaft 52 is also longitudinally slidable this time on top support rotatable sleeves (typically at 66) fixedly mounted on support beam (typically at 68 and shown in dotted lines). Both top shaft 52 and bottom shaft 54 are rotatable under the power of a pair of hydraulic cylinders (typically at 57) each mounted at opposite their ends on rotation arms 59 and 61 which are themselves fixedly mounted, in convenient interstices through rear bracket 60, around top shaft 52 and bottom shaft 54, respectively. The servo hydraulic cylinders 57 are under the control of the computer which will direct them, at the appropriate time, to rotate expand thereby rotating to shaft 52 and bottom shaft 54 in opposite directions thereby enabling to approach the top spiked roller 58 towards its bottom counterpart to effectively clamp a board 12. Hence, servo hydraulic cylinders 57 under the control of the computer (not shown) can be made to expand thereby clamping together spiked rollers 58 and later caused to contract thereby distancing spiked rollers 58. It is to be understood that when the spiked rollers 58 have clamped a board 12, the rear bracket 60 can immediately thereafter be displaced backwards to cause the required transverse movement, in unison, of clamping assembly 48 and board 12 in the direction indicated by arrow 1. Once board 12 has completed its transverse movement, it would then be in longitudinal alignment with its preferred feeding path and the servo hydraulic cylinders 57 would then be directed by the computer to rotate top shaft 52 and bottom shaft 54 to their initial positions thereby releasing board 12 for further processing. Immediately thereafter, rear bracket 60 along with clamping assembly 48 would be slid back to their initial position in readiness for clamping and moving the next board 12.
Referring now to FIGS. 1 and 7, a preferred embodiment of eccentric arm assembly 50 will now be described in further detail. In FIG. 7 there is shown a schematic view of eccentric arm assembly 50. The assembly 50 is powered by a suitable hydraulic motor 70 under the control of the computer. A sprocket wheel 72 is mounted on the output shaft 74 (shown in dotted lines) of the motor 70 and is linked by chain 76 to a larger sprocket drive wheel 78. Referring also to FIG. 1, torque shaft 80 is fixedly mounted through drive wheel 78 and will therefore rotate in unison with drive wheel 78. Torque shaft 80 is rotatably supported on bearing packed sleeve blocks 82 and 84 themselves bolted to support beams 86 and 88, respectively. On both longitudinal ends of cross-shaft 80, there are fixedly mounted similar eccentric arms 90 and 92. The eccentric arm assembly 50 will now only be further described with regards to its side closest to drive wheel 78. It is to be understood that a similar mechanism is present at the other longitudinal end of torque shaft 80 as can be seen in FIG. 1. It is also to be understood that both sides of eccentric arm assembly 50 move in unison under the power of electric motor 70 because of the torque shaft 80.
Turning again to FIG. 7 eccentric arm 90 is fixedly mounted near one of its ends onto torque shaft 80. Sleeve block 82 remains in a support position between drive wheel 78 and eccentric arm 90. On the other end of eccentric arm 90 there is pivotally connected the proximate end of a linking member 94. At its distal end, linking member 94 is also pivotally connected to rear bracket 60. In operation, the rotation of torque shaft 80 will be powered by drive wheel 78 under control of the computer. Upon rotation of torque shaft 80, eccentric arm 90 will alternatively pull or push linking member 94 together with rear bracket 60, top shaft 52, and bottom shaft 54. This back and forth movement will correspond to the constant transverse distance C travelled by each board 12. The eccentric arm assembly 50 embodies the important benefit of gradually accelerating and decelerating clamping assembly 48. The length of eccentric arm 90 and the gear ratio of drive wheel 78 to sprocket wheel 72 is of course chosen to effect movement of clamping assembly 48 equal to the constant distance C and at a suitable pace during operation. Ideally, these components would be sized so that motor 70 would operate in a single direction and briefly pause when the eccentric arm assembly 50 is in full extension (as shown for example in FIGS. 1 and 6) to allow clamping of a board 12, and resume its rotative energy and briefly pause again when the eccentric arm assembly 50 is in complete retraction to allow the release of board 12 in alignment with its preferred feeding path. This cycle would of course be repeated for each board 12.
Referring now to FIGS. 4 and 5, the propulsion of board 12 into the edger unit (not shown) will now be described in further detail. Once board 12 has been placed in longitudinal alignment with its preferred feeding path in accordance with the present invention, and before the board 12 is released from the clamping assembly 48, a series of spiked feed rollers (typically at 96) located immediately above board 12 and along its length will be lowered by hydraulic cylinders (typically at 98) onto board 12. This will press board 12 against corresponding motorized spiked feed rollers 100 located immediately below board 12 which will propel board 12 longitudinally along the direction indicated by arrow 2 into motorized top and bottom spiked feed rollers assembly 101 and finally into the edger unit (not shown). It is to be noted that in operation, the board 12 will not be released by clamping assembly 48 before it is seized and starts to be longitudinally propelled by the series of spiked feed rollers 96 and 100. This is of course possible since the spiked rollers 58 of clamping assembly 48 are freely rotatable in the same direction as spiked feed rollers 96 and 100.
Various other alternative or optional embodiments of infeed system 10 will now be described wherein like reference numerals indicate components common to this these alternative or optional embodiments.
Referring now to FIG. 4, an alternative embodiment of the infeed system 10 is shown. The embodiment shown is designed to effectively handle boards of varying size and length as exemplified by board 12 and board 106. In this embodiment, a third endless transverse transport chain 102 is in a space relation to endless chain 20 and a third endless transverse transport chain 102 is in a spaced relation to endless transverse transport chain. Obviously chains 18, 20, and 102 are driven in unison by torque shaft 19 and shaft 21 connected to an electric motor (not shown) under the control of the computer (not shown). Similarly, chains 32, 34, and 104 are also driven in unison by torque shaft 33 and shaft 35 also connected to an electric motor (not shown) under the control of the computer (not shown). This embodiment will permit to handle longer boards such as board 106 which would otherwise be to long for the previously described embodiment.
Referring now to FIGS. 6 and 9, there is shown an optional embodiment of the infeed system 10. This embodiment is specifically adapted to provide an infeed system 10 which prevents boards 12 from slipping, bouncing, or sliding during their positioning in abutment against positioning pegs 26 and 28 for subsequent alignment with a preferred edging path. In FIG. 8 top friction shoes 108 and 110 are bolted on support beam 112 to overhang immediately above endless chains 32 and 34, respectively. Each friction 108 and 110 is of similar construction and consequently only one of the friction shoes, namely friction shoe 110 will be further described. Friction shoe 110 has a triangular flange 114 bolted onto support beam 112. Turning now to FIG. 6, friction shoe 110 is schematically illustrated in operation in a sectional view without triangular flange 114. Friction shoe 110 comprises four sprocket wheels (typically at 116) mounted on suitable axles (typically at 118) around which a chain belt 120 is placed to be driven on the sprocket wheels 116. A grooved teflon® block 122 is suspended on resilient levers 124 and 126 to maintain tension on chain belt 120 so that a relatively flat portion of chain belt 120 is maintained in close parallel proximity to endless transport chain 34. Turning back to FIG. 8, one of sprocket wheels 116 is driven by drive shaft 128 which extends in a direction parallel to support beam 112 to drive a similar sprocket wheel 130 on friction shoe 108 and further extends through friction shoe 108 through a bored support flange 132 to a drive sprocket wheel (not shown) motorized by an electric motor and chain assembly (not shown) under the control of the computer (not shown).
In operation, chain 120 on each friction shoe 108 and 110 will be driven at the same linear velocity as their counterpart endless transport chains 32 and 34. It is to be understood that in this way a board 12 will be positively advanced, while minimizing its bounce or slippage, to positioning pegs 26 and 28. The resilient levers 124 and 126 on each friction shoe 108 and 110 will allow chain belt 120 to resiliently conform itself to the specific shape and thickness of a board 12. This particular embodiment is a preferred embodiment when boards 12 are being processed by the infeed system 10 while frozen or wet.
In FIG. 9 there is shown another embodiment of infeed system 10 capable of feeding workpieces of varying dimensions to more than one edger unit (not shown) in accordance with the particular size of each workpiece entering the infeed system 10. In this particular embodiment, workpieces of substantially different dimensions, exemplified by boards 12 and 134 will sequentially pass through optical scanning station 16. The size and morphology data from optical scanning station 16 will be relayed to a computer (not shown) which will calculated a preferred feeding path into a preferred edger unit. In this particular embodiment, infeed system 10 is shown as capable of alternatively feeding boards into two possible edger units (not shown) in parallel directions exemplified by arrows 2 and 2'. For example, a smaller board such as board 12 would be fed generally in the direction indicated by arrow 2 while a larger board such as board 134 would be fed generally in the direction indicated by arrow 2'.
In operation, positioning pegs 26 and 28 will be moved by servo positioner cylinders 40 as directed by the computer (not shown) so that a board 12 or 134 will travel a variable transverse distance X and reach abutment on pegs 26 and 28 in accordance with a calculated preferred feeding path alternatively in the general direction of arrows 2 or 2'. The computer (not shown) will then direct eccentric arm assembly 50 to further transversely displace board 12 or 134 by a constant distance C so that board 12 or 134 will reach its alignment with a preferred feeding path into one of two edger units (not shown). In this embodiment, eccentric arm assembly 50 is provided with servo hydraulic cylinders 136 and 138 on each linking arm 94 thereby making it possible for the computer (not shown) to direct the elongation or retraction of each linking arm 94. Therefore, clamping assembly 48 can be adequately positioned above and below boards 12 or 134 to seize and transport boards 12 or 134 to their respective preferred feeding path when the eccentric arm assembly 50 is activated as previously described. Once boards 12 or 134 have reached longitudinal alignment with their respective preferred feeding path, they will be propelled longitudinally into the appropriate edger unit (not shown) spiked feed rollers located immediately above and below boards 12 or 134 (typically at 96, 140, 142, 144, 146, and 101). As illustrated in FIG. 9, a workpiece of the dimensions exemplified by board 12 would be propelled in the general direction indicated by arrow 2 by the assemblies of spiked feed rollers (typically at 96, 146, and 101). As for a workpiece of the dimensions exemplified by board 134 it would be propelled in the general direction indicated by arrow 2' by the assemblies of spiked feed rollers (typically at 96, 142, 140, 146, and 101). As further illustrated in FIG. 9, it is to be understood that spiked feed rollers typically shown at 146 and 148 are of wider longitudinal construction to operably propel workpieces of various dimensions into either of the edger units (not shown).
It is to be noted that throughout this description, it is obviously assumed that sprocket wheels, or other rotatable or otherwise mobile parts are to be installed with appropriate bearings or lubrication so as to minimize frictional forces and energy consumption. Additionally, it is to be understood that the infeed system 10 is to be firmly affixed to the floor of the mill where it is in operation so that it will be stable as precise alignment of workpieces into the edger units is required.
Although the invention has been described above with respect to specific embodiments, it will be evident to a person skilled in the art that it may be modified and refined in various ways. It is therefore wished to have it understood that the present invention should not be limited in scope, except by the terms of the following claims. | 4y
|
FIELD OF INVENTION
[0001] The present invention deals with curcumin nanoparticles and curcumin bound to chitosan nanoparticles which enhance curcumin bioavailability.
BACKGROUND OF THE INVENTION
[0002] Curcumin a polyphenolic component of the plant Curcuma longa is an interesting molecule because of the variety of biological activities it possesses. Prominent among them are anti-inflammatory and cancer chemopreventive activities (Ammon et al. Pharmacology of Curcuma longa , Planta Med., 1-7, 1991). Curcumin's effect on proteins whose abnormal functioning leads to Alzheimer's disease demonstrates the possibility of developing better drugs for the same disease using curcumin or its derivatives. (Ringman et al. A Potential Role of the Curry Spice Curcumin in Alzheimer's Disease. Curr Alzheimer Res 2005; 2:131-136).
[0003] Curcumin has been shown to possess wide range of pharmacological activities including antimicrobial effect (Negi et al., 1999. Antibacterial Activity of Turmeric Oil: A Byproduct of curcumin Manufacture, Journal of Agricultural and Food Chemistry 47(10), 4297-4300), reducing the incidence of cholesterol gallstones (Hussain et al., 1992 Effect of curcumin on cholesterol gall- stone induction in mice, Indian J. Med. Res., 96: 288-291), protection of liver injury from both alcohol and drugs (Nanji et al. 2003 Curcumin prevents alcohol-induced liver disease in rats by inhibiting the expression of NF-kappa B-dependent genes, Am. J. Physiol. Gastrointest. Liver Physiol., 284 (2), G321-327, and Venkatesan et al., 1995, G., Modulation of cyclophosphamide-induced early lung injury by curcumin, an anti-inflammatory antioxidant, Mol. Cell. Biochem., 142 (1), 79-87). Recently its in vitro anti-parasitic activity against Leishimania has been described (Saleheen et al., 2002. Latent activity of curcumin against leismaniasis in vitro. Biol. Pharm. Bull. 25, 386-389.) and it has the ability to hinder Trypanosoma and Plamodium viability (Nose et at., 1998 Trypanocidal effects of curcumin in vitro, Biol. Pharm. Bull. 21,643-645. and Padmahaban, (Curcumin for malaria therapy, BBRC)
[0004] But the major problem for curcumin's use in therapy thus far has been it's poor bioavailability. In the view of the high lipophilic character of curcumin molecule, one would expect the body fat to contain a high proportion of bound curcumin. The poor absorption from intestine, coupled with the high degree of metabolism of curcumin in the liver and its rapid elimination in the bile, makes it unlikely that high concentrations of the substance would be found in the body long after ingestion. These pharmacokinetic properties of curcumin have been confirmed by using HPLC technique. Thus the systemic bioavailability of curcumin is low, 75% being excreted in the feces and only traces appeared in the urine (Wahlstrom et at., 1978 A study on the fate of curcumin in the rat. Acta Pharmacologica et Toxicologica 43, 86-92).
[0005] Due to the numerous therapeutic indications in which curcumin can be used, enhanced bioavailability of curcumin in the near future is likely to bring this promising natural product to the forefront of therapeutic agents for treatment of various human diseases. There have been attempts made in the prior art to increase the bioavailability of curcumin. To improve the bioavailability of curcumin, numerous approaches have been undertaken.
[0006] WO/2007/103435 provides curcuminoid compositions that exhibit enhanced bioavailability and is provided as microemulsion, solid lipid nanoparticles (SLN), microencapsulated oil or the like.
[0007] WO/2008/043157 provides compositions for modulating an immune response, which may be contained in one or more particles such as nanoparticles or microparticles. In some embodiments, the particle comprises a polymeric matrix or carrier, illustrative examples of which include biocompatible polymeric particles.
[0008] WO/2006/022012 describes a novel and stable solid dispersion of curcumin produced by dissolving curcumin together with polyvinylprrloidone in an alcoholic solvent and then spray-drying.
[0009] CN1736369 provides a curcumin oil emulsion and injection, wherein the emulsion comprises curcumin, oil, emulsifying agent and water.
[0010] Savita Bisht el al ( Polymeric nanoparticle-encapsulated curcumin (“nanocurcumin”): a novel strategy for human cancer therapy , J Nanobiotechnology. 2007; 5: 3.) disclose polymeric nanoparticle encapsulated formulation of curcumin—nanocurcumin—utilizing the micellar aggregates of cross-linked and random copolymers of N-isopropylacrylamide (NIPAAM), with N-vinyl-2-pyrrolidone (VP) and poly(ethyleneglycol)monoacrylate (PEG-A).
[0011] Curcumin delivered through liposomes has been shown to be effective in suppressing pancreatic carcinoma growth in murine xenograft models. (Li L, Braiteh FS, Kurzrock R. Cancer 2005;104:1322-31). But the drawback of any liposomal prepration is its instability under physiological conditions and under storage conditions (T. Ruysschaert, M. Germain, J. F. Gomes, D. Fournier, G. B. Sukhorukov, W. Meier and M. Winterhalter, IEEE Trans. Nanobiosci . 2004, 3, 49-55 & Sukhorukov, A. Fery and H. Mohwald, Intelligent micro- and nanocapsules, Prog. Polym. Sci . 2005, 885-897). Repeated administration of liposome may have some effect on age related diseases including cardiovascular diseases, malignancy and autoimmune diseases. (G. Fernandes, Current Opinion in Immunology, 1989-90,2, 275-281).
[0012] N-isopropylacrylamide, N-vinyl-2-pyrrolidone and poly(ethyleneglycol)monoacrylate have also been tried for the preparation of curcumin nanoparticles in prio art. A study conducted by J Sakamoto and K Hashimoto using rats shows that oral administration of N-isopropylacrylamide to rats , in drinking water for 45 days can induce severe signs of neuropathy as well as body weight loss (J Sakamoto et al, Archives of toxicology, 1985, 57, 282-4.) Another study conducted by K Hashimoto, J Sakamoto and H Tanii using acrylamide and related compounds showed that N-isopropylacrylamide when given orally to mice caused neurotoxicity and testicular atrophy. (Archives of toxicology, 1981, 47, 179-89). Therefore, long term use of such nano particles can not be recommended without toxicity studies.
[0013] The curcumin nanoparticles and chitosan nanoparticles coated with curcumin when fed orally to mice showed improved bioavailability of curcumin and cured Plasmodium yoelii infected mice.
SUMMARY OF THE INVENTION
[0014] The present invention provides curcumin nanoparticles made out of curcumin only and curcumin bound to chitosan nanoparticles. The bioavailability of curcumin from such nanoparticles, in particular, was tested by determining it's ability to cure Plasmodium yoelii infection in mice. Bioavailability of curcumin in mice from the invented formulations increased by 10 fold. Curcumin from said nanoparticles was also seen to persist in mice for a longer duration as compared to curcumin administered in olive oil thereby increasing the efficacy of the treatment.
DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0015] FIG. 1.1 DLS of curcumin bound to Chitosan nano particles
[0016] FIG. 1.2 DLS of Curcumin nano particles
[0017] FIG. 1.3 Zeta potential of different nano particles
[0018] FIG. 1.4 Viscocity of different nano particles
[0019] FIG. 2.1 TEM picture of Chitosan nano particles
[0020] FIG. 2.2 TEM Picture of curcumin bound to chitosan nano particles
[0021] FIG. 2.3 TEM Picture of curcumin nano particles
[0022] FIG. 3 Increase in bioavailability of curcumin when delivered bound to chitosan nano particle, or as nano particle or delivered through olive oil
[0023] FIG. 4.1 Parasitemia in Infected Control Group
[0024] FIG. 4.2 Parasitemia in Olive oil Control Group
[0025] FIG. 4.3 Parasitemia Chitosan nano particle Control Group
[0026] FIG. 4.4 Parasitemia in Curcumin in olive oil Group
[0027] FIG. 4.5 Parasitemia in Curcumin bound to chitosan nanoparticle Group
[0028] FIG. 4.6 Parasitemia in Curcumin nanoparticle Group
[0029] FIG. 5.1 FACS analysis of RBC taken from uninfected mouse not fed with curcumin nanoparticles
[0030] FIG. 5.2 FACS analysis of RBC taken from Normal mouse fed with curcumin nanoparticles
[0031] FIG. 5.3 FACS analysis of RBC taken from infected mouse fed with curcumin nanoparticles
[0032] FIG. 5.4 FACS analysis data showing curcumin fluorescence intensity of uninfected and infected RBC
[0033] FIG. 5.5 Accummulation of curcumin in infected RBC taken from mouse with different parasitemia who were fed with curcumin nanoparticles
[0034] FIG. 5.6 Confocal microscopy showing the accumulation of curcumin in erythrocytes of uninfected mice fed with curcumin nanoparticles
[0035] FIG. 5.7 Confocal microscopy showing the accumulation of curcumin in erythrocytes of nfected mice fed with curcumin nanoparticles
[0036] FIG. 6 In vivo inhibition of hemozoin synthesis in P. yoelii infected mice by feeding chloroquinine in normal saline or curcumin bound to chitosan nanoparticles (hemozoin concentration is measured in terms of dissociated home)
[0037] FIG. 7 TUNEL assay showing apoptosis in isolated parasite from infected mice fed with curcumin bound to chitosan nanoparticles.
A. Control mice receiving no treatment shows very little apoptosis (0.18%). B. Infected mice given only chitosan nanoparticles orally showed 4.6% apoptosis. C. Infected mice given only curcumin through olive oil orally showed 4.47% apoptosis. D. Infected mice given curcumin bound to chitosan nanoparticles orally showed 9.64% apoptosis.
[0042] FIG. 8 Summary of the TUNEL assay described in FIG. 7
[0043] FIG. 9.1 FTIR spectra of chitosan
[0044] FIG. 9.2 FTIR spectra of Chitosan nanoparticles
[0045] FIG. 9.3 FTIR spectra of Curcumin
[0046] FIG. 9.4 FTIR spectra of Curcumin nanoparticles
[0047] FIG. 9.5 FTIR spectra of Curcumin bound to chitosan nanoparticles
[0048] FIG. 10.1 Matrix Assisted Laser Desorption Ionization (MALDI) profile of Curcumin indicating the presence of the three curcuminoids in the sample i.e curcumin (mass 369) , Demethoxycurcumin (mass 339) and Bisdemethoxycurcumin (mass 309)
[0049] FIG. 10.2 MALDI profile of Curcumin nanoparticles indicating the presence of the same molecules ie curcumin (mass 369), Demethoxy curcumin (339) and Bisdemethoxy curcumin (309).
[0050] FIG. 10.3 HPLC profile of Curcumin separated on a C-18 column using an isocratic solvent system: acetonitrile: methanol: water: acetic acid::41: 23: 36:1.
[0051] FIG. 10.4 HPLC profile of Curcumin nanoparticles separated on a C18 column after dissolving in ethanol using the same isocratic solvent system for separation. It shows the same profile as curcumin.
[0052] FIG. 11 Effect of oral intake of curcumin and nanocurcumin on fasting glucose level of human volunteers.
[0053] FIG. 12.1 Effect of oral intake of curcumin and nanocurcumin on Urea level of human Volunteers
[0054] FIG. 12.2 Effect of oral intake of curcumin and nanocurcumin on creatinine level of human volunteers
[0055] FIG. 12.3 Effect of oral intake of curcumin and nanocurcumin on potassium level of human volunteers (Only Seven Volunteers)
[0056] FIG. 13.1 Effect of oral intake of curcumin and nanocurcumin on Total cholesterol level of human volunteers
[0057] FIG. 13.2 Effect of oral intake of curcumin and nanocurcumin on HDL cholesterol level of human volunteers
[0058] FIG. 13.3 Effect of oral intake of curcumin and nanocurcumin on LDL cholesterol level of human volunteers
[0059] FIG. 13.4 Effect of oral intake of curcumin and nanocurcumin on Triglycerides level of human volunteers
[0060] FIG. 13.5 Effect of oral intake of curcumin and nanocurcumin on sodium level of human Volunteers.(Only Seven Volunteers)
[0061] FIG. 14.1 Effect of oral intake of curcumin and nanocurcumin on Hemoglobin level of human volunteers
[0062] FIG. 14.2 Effect of oral intake of curcumin and nanocurcumin on RBC count level of human volunteers
[0063] FIG. 15.1 Effect of oral intake of curcumin and nanocurcumin on SGPT level of human volunteers
[0064] FIG. 15.2 Effect of oral intake of curcumin and nanocurcumin on SGOT level of human volunteers
[0065] FIG. 15.3 Effect of oral intake of curcumin and nanocurcumin on ALP level of human volunteers
[0066] FIG. 15.4 Effect of oral intake of curcumin and nanocurcumin on total Bilirubin level of human volunteers
[0067] FIG. 15.5 Effect of oral intake of curcumin and nanocurcumin on albumin level of human volunteers
[0068] FIG. 16.1 Effect of oral intake of curcumin and nanocurcumin on globulin level of human volunteers
[0069] FIG. 16.2 Effect of oral intake of curcumin and nanocurcumin on eosinophiles level of human volunteers
[0070] FIG. 16.3 Effect of oral intake of curcumin and nanocurcumin on neutrophils level of human volunteers
[0071] FIG. 16.4 Effect of oral intake of curcumin and nanocurcumin on platelet count level of human volunteers
DETAILED DESCRIPTION
[0072] The term “organic acid” refers to any organic compound with acidic properties. Representative examples include but are not limited to acetic acid, citric acid and propionic acid.
[0073] The term “alcohol” refers to any organic compound in which a hydroxyl group (—OH) is bound to a carbon atom of an alkyl or substituted alkyl group. Representative examples include but are not limited to ethanol, methanol and propanol.
[0074] In the present invention curcumin nanoparticles were prepared. In one embodiment, nanoparticles were also made out of the mucoadhesive biopolymer chitosan to deliver curcumin orally into mice. Curcumin was loaded on the surface of the chitosan nanoparticles. This more efficient delivery vehicle ensured enhanced bioavailability and sustained circulation of curcumin in the blood compared to oral delivery of curcumin alone dissolved in olive oil. Importantly, this procedure does not involve any chemical modification of curcumin and binding occurs due to the availability of hydrophobic pockets on the surface of the chitosan nanoparticles. Chitosan nanoparticles not only improved the bioavailability of curcumin but also increased its stability.
[0075] The process involved dissolving a clear solution of Chitosan in an organic acid by heating the mixture at 50° C.-80° C. The mixture was rapidly cooled to 4° C.-10° C. and this process was repeated till a clear solution was obtained. The solution was then heated at 50° C.-80° C. and sprayed under pressure into water kept stirring at 2° C.-10° C. This solution containing the Chitosan nanoparticles was stored for further use. The chitosan nanoparticles can be concentrated by centrifugation at slow speed. A clear solution of curcumin was prepared in alcohol. This curcumin solution was added under pressure to vigorously stirred aqueous suspension of chitosan nanoparticles in an organic acid and the resulting suspension was stirred overnight at room temperature to load curcumin on the chitosan nanoparticle. For the release study, curcumin-chitosan nanoparticles suspension was centrifuged and the pellet was resuspended with equal volume of water and was centrifuged two more times with purified water to remove unbound curcumin from the nano particles.
[0076] Accordingly in one embodiment the process involved dissolving a clear solution of 0.025%-1% (w/v) Chitosan in 0.1% -10% or more, preferably 0.5%-1% aqueous acetic acid by heating the mixture at 50° C.-80° C. The mixture was rapidly cooled to 4° C.-10° C. and this process was repeated till a clear solution was obtained. The solution was then heated at 50° C.-80° C. and sprayed under pressure into water kept stirring at 200-1400 rpm at 4° C.-10° C. This solution containing the Chitosan nanoparticles was stored for further use. The chitosan nanoparticles can be concentrated by centrifugation at slow speed. A clear solution of 0.1-1.0 g of curcumin was prepared in 100-1000 ml of ethanol. This curcumin solution was added under pressure to vigorously stirred aqueous suspension of chitosan nanoparticles in 0.1%-10% or more, preferably 0.25% -1% acetic acid and the resulting suspension was stirred overnight at room temperature to load curcumin on the chitosan nanoparticle. For the release study, curcumin-chitosan nanoparticles suspension was centrifuged and the pellet was resuspended with equal volume of water and was centrifuged two more times with purified water to remove unbound curcumin from the nano particles.
[0077] In the case of curcumin bound to chitosan nanoparticles, the concentrations of both chitosan and curcumin affect the size of the nanoparticle.
[0078] In another embodiment of the invention, curcumin nanoparticles were prepared by dissolving curcumin in alcohol and then spraying the solution kept at 25° C.-40° C. under nitrogen atmosphere and high pressure into an organic acid solution kept stirring at room temperature. Stabilizers or surfactants were not used and the finished product entirely consisted of curcumin in the form of nanoparticles.
[0079] Accordingly, curcumin nanoparticles were prepared by dissolving 0.1-1 g curcumin in 100-1000 ml 5%-100% of ethanol, preferably absolute ethanol and then spraying the solution kept at 25° C.-40° C. under nitrogen atmosphere and high pressure into 0.1%-10% or more, preferably 0.25%-0.1% aqueous acetic acid solution kept stirring at room temperature. Stabilizers or surfactants were not used and the finished product entirely consisted of curcumin in the form of nanoparticles.
[0080] Dynamic light scattering (DLS) (Malvern, Autosizer 4700) was used to measure the hydrodynamic diameter and size distribution (polydispersity index, PDI= — μ2 — /Γ2). Chitosan loaded curcumin nanoparticles of size 43 nm to 325 nm, preferably 43 nm to 83nm, and curcumin nanoparticles of size 50 nm to 250 nm, preferably 50 nm to 135 nm were obtained as indicated in FIGS. 1.1 & 1 . 2 . The zeta potential and viscosity of nanoparticles was measured on a zeta potential analyzer (Brookhaven, USA) and a Viscometer FIGS. 1.3 & 1 . 4 . Particle morphology was examined by transmission electron microscopy (TEM) (Hitachi, H-600). FIGS. 2 . 1 - 2 . 3
[0081] Nanoparticles were dried in a vacuum dessicator and their FTIR were taken with KBr pellets using the Nicolet Magna 550 IR Spectrometer FUR spectra of Chitosan nano particle has similar absorbance pattern as that of chitosan. (FIGS. 9 . 1 - 9 . 2 ). Similarly the FTIR spectra of curcumin and curcumin nano particles were similar indicating that curcumin was not chemically modified when it is converted into nanoparticles (FIGS. 9 . 3 - 9 . 4 ). The FTIR spectra of curcumin bound to chitosan nano particles as expected had all the features of chitosan and curcumin indicating the curcumin is not altered in the process of binding to chitosan nano particles ( FIG. 9.5 ).
[0082] Both the curcumin nanoparticle and the curcumin bound to chitosan nanoparticle cured 100% of the mice infected with a lethal strain of Plasmodium yoelii parasite compared to infected untreated control where all animals died FIG. 4 . 1 - 4 . 6 . The cured mice populations survived for at least 100 days and were resistant to subsequent reinfection in 100% cases. It was found that curcumin preferentially accumulated inside the infected erythrocytes, the quantity increasing with increase of parasite load in the erythrocyte FIG. 5.5 . Confocal microscopy revealed that curcumin was bound to the parasite FIG. 5.7 . Just like chloroquine, curcumin inhibited hemozoin formation in vivo which the parasite makes to avoid the toxicity of heme ( FIG. 6 .)
[0083] Curcumin nanoparticles and curcumin bound to chitosan nanoparticles demonstrated a 10 fold increase in bioavailability of curcumin ( FIG. 3 .) and they were efficient in killing malaria parasite in vivo in mice. FIG. 4 . 5 - 4 . 6 .
[0084] The scope of the invention extends to all possible pharmacological uses of curcumin such as use of curcumin in the treatment of cancers, diseases involving an inflammatory reaction, alzheimer's disease, cholesterol gall stones, diabetes, alcohol and drug induced liver diseases, parasitic infestation, malaria and other parasitic diseases, neurological disorders and all other diseases that can be treated or managed using curcumin.
EXAMPLE 1
Preparation of Curcumin Bound to Chitosan Nanoparticles
[0085] 1.1 Preparation of Chitosan Nanoparticles
[0086] A clear solution of 0.2% Chitosan (w/v) in 1% acetic acid was prepared by heating the mixture to 75° C. The mixture was rapidly cooled to 4° C. and this process was repeated several times till a solution of chitosan was obtained. This solution was then heated to 75° C. again and sprayed under pressure into water kept stirring very rapidly at 4° C. This ensured production of uniformly dispersed chitosan nanoparticles which can be concentrated by centrifugation
[0087] 1.2 Loading Curcumin on Chitosan Nanoparticles
[0088] A clear solution of 1 gm of curcumin in 1000 ml of absolute ethanol was added under pressure to vigorously stirred aqueous suspension of chitosan nanoparticles in 1% acetic acid and the resulting suspension was stirred overnight at 200 -1400 rpm at room temperature to load curcumin on the chitosan nanoparticle.
EXAMPLE 2
Preparation of Curcumin Nanoparticles
[0089] 1 gm of curcumin was dissolved in 1000 ml of absolute ethanol. The solution was kept at 40° C. and then sprayed under nitrogen atmosphere and high pressure into 0.1% aqueous acetic acid solution which was kept stirring at 200 -1400 rpm at room temperature. This lead to the production of uniformly dispersed curcumin nanoparticles. The particle size can be controlled by varying the pressure at which curcumin solution is sprayed into 0.1% aqueous acetic acid kept at different temperatures (25° C. -40° C.).
EXAMPLE 3
Biophysical Characterization of Nanoparticles
[0090] 3.1 Particles Size Measurement by Dynamic Light Scattering
[0091] Dynamic light scattering (DLS) was used to measure the hydrodynamic diameter and size distribution (FIG. 1 . 1 - 1 . 2 ). Dynamic light scattering (DLS) experiments were performed (scattering angle=90°, laser wavelength=632.8 nm) on a 256 channel Photocor-FC (Photocor Inc., USA) that was operated in the multi-tau mode (logarithmically spaced channels). During the titration process, a few milliliters of the sample was drawn from the reaction beaker and loaded into borosilicate cylindrical cell (volume=5 ml) and DLS experiment performed. The data was analyzed both in the CONTIN regularization and discrete distribution modes (multi-exponential). The CONTIN software generates the average relaxation time of the intensity correlation function, which is solely related to Brownian dynamics of the diffusing particles for dilute solutions. The intensity correlation data was force fitted to a double-exponential function without success. Thus, we have relied on a single exponential fitting (with polydispersity) and the chi-squared values were>90% consistently for all the correlation data. This yielded the apparent translational diffusion coefficient values. Correspondingly, the apparent hydrodynamic radii, R h of the particles, at room temperature (°C.) were determined from the knowledge of translational diffusion coefficient D Γ . These values were used in Stoke-Einstein equation, D=k B Γ/f with the translational friction coefficient, f=6πη 0 R h , where k B is Boltzmann constant, and n 0 is solvent viscosity.
[0092] 3.2 Electrophoresis Studies
[0093] Electrophoretic mobility measurements were performed on the prepared nanoparticles ( FIG. 1.3 ). The instrument used was Zeecom-2000 (Microtec Corporation, Japan) zeta-sizer that permitted direct measurement of electrophoretic mobility and its distribution. In all our measurements the migration voltage was fixed at 25 V. The instrument was calibrated against 10 −4 M AgI colloidal dispersions. All measurements were performed in triplicate.
[0094] 3.3 Particle Morphology by Transmission Electron Microscopy
[0095] Particle morphology was examined by transmission electron microscopy (TEM) (Hitachi, H-600). Samples were immobilized on copper grids. They were dried at room temperature, and subsequently examined using transmission electron microscope after staining with uranyl acetate (FIG. 2 . 1 - 2 . 3 ).
EXAMPLE 4
Evidence of Binding of Chitosan Nanoparticles with Curcumin
[0096] Chitosan nanoparticles and Chitosan nanoparticles loaded with curcumin were separated from suspension and were dried., and their FTIR was recorded with KBr pellets on Nicolet, Magna-550 spectrum. HPLC was performed after extracting curcumin from the nanosuspension. The particles were collected after high centrifugation and washed several times till the presence of curcumin was not detected in the supernatant by spectroscopic measurnent (absorbance recorded at 429 nm against ethanol). Curcumin was extracted from the pellet by the extraction solvent consisting of ethyl acetate and isopropanol (9:1). The upper organic layer was dried under nitrogen atmosphere. It was then reconstituted in ethanol and absorbance was recorded at 429 nm against ethanol as blank.
[0097] HPLC was performed using C18 column and isocratic solvent system consisting of acetonitrile: methanol: water: acetic acid::41:23:36:1, at a flow rate of 1 ml/min. Mass was determined by using MALDI-TOF mass spectrophotometer from Bruker Daltonik GmbH, (Germany). Curcumin was dissolved in ethanol while curcumin nanoparticles were resuspended in 20% ethanol and the mass spectra was recorded. Both curcumin and curcumin nanoparticles showed the presence of curcumin (mass 369), Demothoxy curcumin (339) and bisdemethoxy curcumin (309) indicating that the original molecules present in the curcumin sample are not modified by conversion to curcumin nanoparticles ( FIGS. 10.1 and 10 . 2 ).
[0098] Viscosity of Nanoparticles: The viscosity of individual nanoparticle suspension was measured at room temperature and normal atmospheric pressure. The result indicates a change in viscosity of chitosan nanoparticles bound to curcumin from that of chitosan nanoparticles and curcumin nanoparticles (FIG. 1.4). This indicates binding of curcumin to chitosan which also correlates with changes in zetapotential of chitosan nanoparticles bound to curcumin from that of individual nanoparticles, indicating the binding of curcumin to chitosan.
[0000]
TABLE 1
Summary of biophysical properties of the prepared nanoparticles
Mean diameter of
nanoparticles
Viscosity
(distribution of
at
particle size )
21.7° C.
measured by
Zetapotential
Particles
in mPas
DLS
(mV)
Chitosan
5.64
+331.2
Solution(2% Cs in 1%
acetic acid)
Chitosan nanoparticles
3.76
62.3
(43.47-83.56)
+68.542
loaded with curcumin
Curcumin nanoparticles
1.53
115
(50.02-283.21)
−131.372
EXAMPLE 5
Oral Bioavailability of Curcumin in Mice
[0099] Blood samples were obtained at different time intervals, that is, 30 min, 2 h, 4 h and 6 h after oral administration of curcumin (100 mg/kg through olive oil, 160 micrograms per mice through curcumin bound to Chitosan nanoparticles and 160 micrograms per mice through curcumin nanoparticles). Plasma was collected (after heparinization) by centrifugation at 4300 g for 10 min. Plasma (0.5 ml) was acidified to pH 3 using 6 N HCl and extracted twice (1 ml each) using a mixture of ethyl acetate and isopropanol (9:1; v/v,) by shaking for 6 min. The samples were centrifuged at 5000 g for 20 min. The organic layer was dried under inert conditions and the residue was dissolved in an eluent containing ethanol and filtered to remove insoluble material. The amount was quantitated from standard plot of curcumin in ethanol, by measuring the absorbance at 429 nm.
[0100] The identity of curcumin was established by HPLC (C18 column, isocratic solvent system acetonitrile: methanol: water: acetic acid::41:23:36:1, at a flow rate of 1 ml/min) and by MALD1-TOF mass spectrophotometer. (FIG. 10 . 1 - 10 . 4 )
[0101] The increase in bioavailability of curcumin in terms of folds when compared to curcumin delivered through olive oil is depicted in FIG. 3 .
[0102] The results show enhanced bioavailability of curcumin when fed through chitosan nanoparticles and as curcumin nanoparticles along with sustained release in the plasma till 6 hours.
[0000]
TABLE 2.1
Extraction from plasma after 30 minutes post feeding
Conc. of curcumin in micro
grams extracted from
Percentage
Mice Group
Curcumin fed
100 μl of plasma
Bioavailability
Curcumin in
3 mg
1.116 ± 0.146
0.036 ± 0.005
olive oil
Curcumin
160 μg bound
0.64 ± 0.072
0.396 ± 0.041
bound to
to 200 μg of
chitosan
chitosan
nanoparticle
nanoparticle.
Curcumin
160 μg
0.836 ± 0.092
0.5 ± 0.060
nanoparticle
[0000]
TABLE 2.2
Extraction from plasma after 120 min
Conc. of curcumin in
micro grams extracted
Percentage
Mice Group
Curcumin fed
from 100 μl of plasma
Bioavailability
Curcumin in
3 mg
0.621 ± 0.037
0.020 ± 0.0006
olive oil
Curcumin
160 μg bound to
0.613 ± 0.020
0.376 ± 0.015
bound on
200 μg of
chitosan
chitosan
nanoparticle
nanoparticle.
Curcumin
160 μg
0.801 ± 0.059
0.496 ± 0.037
nanoparticle
[0000]
TABLE 2.3
Extraction from plasma after 240 min
Conc. of curcumin in
micro grams extracted
Percentage
Mice Group
Curcumin fed
from 100 μl of plasma
Bioavailability
Curcumin in
3 mg
0.366 ± 0.215
0.007 ± 0.001
olive oil
Curcumin
160 μg bound to
0.493 ± 0.080
0.306 ± 0.050
bound on
200 μg of
chitosan
chitosan
nanoparticle
nanoparticle.
Curcumin
160 μg
0.653 ± 0.094
0.403 ± 0.058
nanoparticle
[0000]
TABLE 2.4
Extraction from plasma after 360 min
Conc. of curcumin in
micro grams extracted
Bioavailability
Mice Group
Curcumin fed
from 100 μl of plasma
Percentage
Curcumin in
3 mg
0.079 ± 0.052
0.002 ± 0.001
olive oil
Curcumin
160 μg bound to
0.116 ± 0.020
0.072 ± 0.013
bound on
200 μg of
chitosan
chitosan
nanoparticle
nanoparticle.
Curcumin
160 μg
0.442 ± 0.584
0.046 ± 0.032
nanoparticle
EXAMPLE 6
Antimalarial Activity of Curcumin Bound to Chitosan Nanoparticles/Curcumin Nanoparticles.
[0103] 6.1 Experimental host and strain maintenance
[0104] Male Swiss mice weighing 25-30 g were maintained on a commercial pellet diet and housed under conditions approved by the Institutional Animal Ethics Commitee of the university. P. yeolli N-67 rodent malarial parasite, was used for infection. Mice were infected by intra peritoneal passage of 10 6 infected erythrocytes diluted in phosphate buffered saline solution (PBS 10 mM, pH 7.4, 0.1 mL). Parasitemia was monitored by microscopic examination of Giemsa stained smears.
[0105] 6.2 In Vivo Antimalarial Activity
[0106] In vivo antimalarial activity was examined in groups of 6 male Swiss mice (25-30 g) intraperitoneally infected on day 0 with P. yeolli such that all the control mice died between day 8 and day 10 post-infection. The mice were divided in to 4 groups of six mice each.
[0107] Untreated control group which was further subdivided into infected control group, olive oil control group and chitosan control group
1. Group treated with curcumin in olive oil control group 2. Group treated with curcumin on chitosan nanoparticles 3. Group treated with curcumin nanoparticles
[0111] For the group treated with curcumin in olive oil, curcumin was suspended in olive oil (100 mg/kg body weight). They were given curcumin at a dose of 3 mg/mice once, suspended in olive oil through the oral route. For the group treated with curcumin bound to chitosan nanoparticles and curcumin nanoparticles, 160 micrograms of curcumin (through chitosan or curcumin nanoparticles) was made available per mouse and was introduced by means of feeding gauge into the oral cavity of non-anesthetized mice as daily doses.
[0112] Each of the groups was infected with 1×10 6 red blood cells taken from an animal having approximately 30% parasitemia. Treatment, in each case, was started only when individual mouse showed parasitemia of 1-3%, that is, by the 4 th day of infection. Survival of mice was monitored for a period of 120 days.
[0113] All the mice in the infected control group and olive oil control group died between 7 th to 11 th day post-infection (FIG. 4 . 1 - 4 . 2 ). All the mice in the chitosan control group died between 7 th to 12 th day post infection (a delay of two days in comparison to the infected control and olive oil control groups) ( FIG. 4.3 ).
[0114] In the group treated with curcumin in olive oil control, 2 out of the 6 mice survived for more than 100 days after cure while 4 died between 10 th to 12 th day post infection ( FIG. 4.4 ).
[0115] All the mice survived in the groups treated with curcumin bound to chitosan nanoparticles and curcumin nanoparticles. All of the mice survived for more than 100 days after cure and were resistant to reinfection by the same parasite (FIG. 4 . 5 - 4 . 6 ).
EXAMPLE 7
Intracellular Localization of Curcumin in Infected Erythrocytes
[0116] 7.1 Intracellular Accumulation of Curcumin in Infected RBC
[0117] Infected Mice with different parasitemia (0% to 17.8%) were given curcumin bound to chitosan nano particles orally. Red blood cells were purified from each mice by density gradient centrifugation and curcumin fluorescence was detected by using FACS. FACS data showing curcumin fluorescence intensity of uninfected and infected RBCs is depicted in FIG. 5 . 2 - 5 . 3 .
[0118] 7.2 Quantitative Estimation of Curcumin Localized/Accumulated in Erythrocytes (Both Infected/Normal)
[0119] Red blood cells from both control and infected mice were purified by density gradient centrifugation, and curcumin was extracted out from 1×10 8 red blood cells using the procedure as described in example 5 and the result shows more accumulation of curcumin in RBC having higher level of parasitemia as indicate in the FIG. 5.5 .
[0120] 7 . 3 Accumulation of Curcumin in Infected Red Blood Cells by Confocal Microscopy
[0121] Slides for confocal microscopy were prepared by fixing erythrocytes or lymphocytes separated by density gradient centrifugation using ficoll from non infected Plasmodium yoelli infected mice fed with curcumin nanoparticles. The isolated cells (erythrocytes) were then sealed with cover slip using mounting medium. Fluorescence imaging of cells was performed with an Olympus Fluoview 500 confocal laser-scanning microscope (Olympus, Tokyo, Japan) equipped with a multi-Argon laser for excitation at 458, 488 and 515 nm. The images were acquired either with 20× objective or a 60× water immersion objective using the fluoview software (Olympus, Tokyo, Japan). The curcumin emission was collected using the barrier filter BA505. The excitation wave length was 458 nm for curcumin. FIG. 5.6-5.7.
EXAMPLE 8
In Vivo Inhibition of Hemozoin Synthesis by Chloroquinine as Well as Curcumin
[0122] Infected mice were divided into 4 groups (each having 4 mice), namely:
1. Control group which was further sub-divided into the infected control group, olive oil control group and chitosan control group 2. Infected and fed with Chloroquinine (1.7 mg in 100 μl of normal saline/mouse/day orally) 3. Infected and fed with Curcumin bound to chitosan nanoparticles (160 μg of curcumin bound to 200 μg of chitosan nanoparticles/per mouse/twice a day) through oral route 4. Infected and fed with Chitosan nanoparticles (200 micrograms of chitosan/day) orally
[0127] Treatment in each group except the control was started when parasitemia had reached ˜10% in each mouse and was carried out for 3 days. Red blood cells were purified on the third day of treatment. Approximately 4×10 7 cells were suspended in 25 mM Tris HCl pH 7.8 containing 2.5% SDS. The cells were centrifuged at 10,000 g for 10 min, supernatant was discarded and the pellet washed in 1 ml of 0.1 M alkaline bicarbonate buffer (pH 9.2). The washed pellet was dissolved in 0.05 ml of 2 N sodium hydroxide and absorbance was read at 400 nm after dilution to 1 ml using 2.5% SDS solution in water. The concentration of heme was calculated by using 90.8 as the milli Molar Extinction coefficient of heme.
[0128] The results of in vivo inhibition of hemozoin synthesis in P. yoelii infected mice by feeding chloroquinine in normal saline or curcumin bound to chitosan nanoparticles (hemozoin concentration is measured in terms of dissociated heme) is depicted in FIG. 6 .
EXAMPLE 9
Detection of Apoptosis
[0129] Terminaldeoxynucleotidyl transferase-mediated deoxyuridine triphosphate biotin nick-end labelling (TUNEL) was performed using the ApoAlert™ DNA Fragmentation Assay kit (R&D Systems). Parasitic cells were isolated from infected RBCs from different groups by density gradient centrifugation. The parasitic cells were washed twice with 1 ml PBS and fixed with 4% formaldehyde/PBS for 25 min at 4° C. After two washes with PBS, the pellet was resuspended in 5 ml permeabilization solution (0.2% Triton X-100 in PBS) and incubated on ice for 5 minutes. Eighty microlitres of equilibration buffer was added and was incubated at room temperature for 5 minutes. The cells were labeled by adding 50 ml TUNEL mix followed by incubation for 60 minutes at 37° C. in a dark, humidified incubator. One millilitre of 20 mM EDTA was then added to terminate the tailing reaction. The samples were washed with PBS and the pellet was resuspended in 250 ml PBS for flow cytometry analysis. The results of this experiment are depicted in FIGS. 7 and 8 .
EXAMPLE 10
Toxicological Studies
[0130] Toxicological studies were carried out on five groups of swiss albino mice and five groups of male wister rats as per the details in table 3.
[0000]
TABLE 3
Toxicological Study using mice and rats fed with PBS, Curcumin
in Olive oil, Chitosan nano particles bound to curcumin,
Chitosan nano particles and Curcumin nanoparticles
Group
Mice
Rat
Group-1
6 female swiss albino mouse.
6 male wister rats
PBS
Given 100 microliters of
Given 1 ml of PBS
PBS orally for 14 days.
orally for 14 days.
Group-2
6 female swiss albino mouse.
6 male wister rats
Curcumin in
Given 4 mg of curcumin
Given 40 mg of curcumin
olive oil
suspended in 100 microliters
suspended in 1 ml of olive
of olive oil orally for 14 days.
oil orally for 14 days.
Group-3
6 female swiss albino mouse.
6 male wister rats
Chitosan
Given 4 mg of curcumin
Given 40 mg of curcumin
nano
bounded to 4 mg of chitosan
bounded to 40 mg of
bounded to
nanoparticles orally for 14
chitosan nano particles
curcumin
days
orally for 14 days
Group-4
6 female swiss albino mouse.
6 male wister rats
Chitosan
Given 4 mg of chitosan
Given 40 mg of chitosan
nano
nanoparticles suspended in
nanoparticles suspended
100 microliters of PBS
in 1 ml of PBS
orally for 14 days
orally for 14 days
Group-5
6 female swiss albino mouse.
6 male wister rats
Curcumin
Given 4 mg of curcumin
Given 40 mg of curcumin
nanoparticle
nanoparticles suspended in
nanoparticles
100 microliters of PBS
suspended in 1 ml
orally for 14 days
of PBS orally for 14 days
EXAMPLE 10a
Histopathological Examination
[0131] Histopathological examination of organs was completed in six animals from each group. The organ taken for histological study from each animal included brain, liver, kidney and heart. Eosin and hematoxylin stained section were available for study from all these organs. No histological evidence of damage to the liver, heart, brain or kidney was seen in any animal in any group. The histological features clearly indicate that the preparations administered by the oral route, that is, curcumin in olive oil, curcumin bound to chitosan nanoparticles, chitosan nanoparticles and curcumin nanoparticles are non-toxic in Wister Rats and Swiss Albino mice.
EXAMPLE 10b
Biochemical Analysis of Mouse and Rat Blood Samples
[0132] Blood samples from members of the five groups of Swiss Albino Mice and Wister Rats after oral feeding to PBS, curcumin in olive oil, curcumin bound to chitosan nanoparticles, chitosan nanoparticles and curcumin nanoparticles as directed in table 3, were subjected to determination of serum glutamic oxaloacetic transaminase (SCOT) level, serum glutamic pyruvic transaminase (SGPT) level, serum urea level, serum creatinine level, serum cholesterol level, serum albumin level and serum hemoglobin level.
[0133] No rise was seen in the serum SGOT, SGPT, urea and creatinine levels after oral feeding of PBS, curcumin in olive oil, curcumin bound to chitosan nanoparticles, chitosan nanoparticles and curcumin nanoparticles. The serum levels of cholesterol, albumin and hemoglobin were also not significantly altered. This indicates that the curcumin nanoparticles of the present invention are non-toxic and safe.
EXAMPLE 11
Effect on Fasting Blood Sugar Levels in Human Volunteers
[0134] Curcumin nanoparticles at a dose of 500 mg/day/person were given orally to nine human volunteers (1, 3, 4, 6, 8, 9, 10, 11 & 12) who gave their informed consent to participate in the study. Their blood glucose level was measured under fasting conditions before the start of the experiment (dark spots) and after 15 day of continuous oral consumption of same quantity of curcumin nanoparticles (white spots) Normal curcumin was given orally to another group of seven human volunteers (2, 5, 7, 13, 14, 15 & 16) at a dose of 500 mg/day/person. The results of the analysis are depicted in FIG. 11 . While fasting glucose level was not altered in the curcumin control group there was a significant decrease in the Nanocurcumin group indicating its ability to lower blood glucose level.
EXAMPLE 12
Effect on Kidney Function in Human Volunteers
[0135] Curcumin nanoparticles at a dose of 500 mg/day/person were given orally to nine human volunteers (1, 3, 4, 6, 8, 9, 10, 11 & 12) who gave their informed consent to participate in the study. Normal curcumin was given orally to another group of seven human volunteers (2, 5, 7, 13, 14, 15 & 16) at a dose of 500 mg/day/person. The level of serum urea, creatinine and potassium (In case of potassium human volunteers(1, 3, 4, 6 were given curcumin nanoparticles where as 2, 5, 7 were given normal curcumin) were measured before the start of the experiment (dark spots) and after 15 day of continous oral comsumption of same quantity of curcumin nanoparticles (white spots). Results of said tests are depicted in FIGS. 12.1- 12 . 3 . The serum creatinine, urea and potassium levels (7 Volunteers) of all the volunteer under the study were within the normal range both before and after 15 days of continous oral consumption. There is slight decrease in serum creatinine and urea levels and increase in potassium level indicating tubular reabsorption of potassium by kidney, thereby showing an overall beneficial effect of curcumin on kidney.
EXAMPLE 13
Effect on Cardiovascular function in Human Volunteers
[0136] Curcumin nanoparticles at a dose of 500 mg/day/person were given orally to nine human volunteers(1, 3, 4, 6, 8, 9, 10, 11 & 12) who gave their informed consent to participate in the study. Normal curcumin was given orally to another group of seven human volunteers (2, 5, 7, 13, 14, 15 & 16) at a dose of 500 mg/day/person. The level were measured before the start of the experiment (dark spots) and after 15 day of continous oral comsumption of same quantity of curcumin nanoparticles (white spots). The effect of curcumin and nanocurcumin was studied on the levels of serum total cholesterol, HDL cholesterol, LDL cholesterol, triglycerides and sodium (In case of sodium only seven human volunteers 1, 3, 4, 6 were given curcumin nanoparticles where as 2, 5, 7 were given normal curcumin). Results of said tests are depicted in FIGS. 13 . 1 - 13 . 5 . A decline in total cholesterol level was seen in the nanocurcumin group consistently as compared to normal curcumin group. Furthermore there is a marked increase in HDL cholesterol (good cholesterol) in case of curcumin nanoparticle group. Level of LDL cholesterol (bad cholesterol) and triglycerides were lowered consistently in curcumin nanoparticle group as compared to normal curcumin group. Decrease in serum sodium level was also observed indicating the promising anti-cholesterolic, anti-stroke, and other beneficial effects on cardiovascular diseases.
EXAMPLE 14
Effect of Oral Intake of Curcumin and Nanocurcumin on Hemoglobin and Rbc Level of Human Volunteers
[0137] Curcumin nanoparticles at a dose of 500 mg/day/person were given orally to nine human volunteers (1, 3, 4, 6, 8, 9, 10, 11 & 12) who gave their informed consent to participate in the study. Normal curcumin was given orally to another group of seven human volunteers (2, 5, 7, 13, 14, 15 & 16) at a dose of 500 mg/day/person. The levels were measured before the start of the experiment (dark spots) and after 15 day of continuous oral consumption of same quantity of curcumin nanoparticles (white spots) The effect of curcumin and nanocurcumin was studied on the levels of blood hemoglobin and RBCs. Results of said tests are depicted in FIGS. 14 . 1 - 14 . 2 , which indicates that there is no adverse effect in terms of induction on anemic condition or lowering of RBC counts following the treatment regime.( ).
EXAMPLE 15
Effect on Liver Inflammation in Human Volunteers
[0138] Curcumin nanoparticles at a dose of 500 mg/day/person were given orally to nine human volunteers (1, 3, 4, 6, 8, 9, 10, 11 & 12) who gave their informed consent to participate in the study. Normal curcumin was given orally to another group of seven human volunteers (2, 5, 7, 13, 14, 15 & 16) at a dose of 500 mg/day/person. The level were measured before the start of the experiment (dark spots) and after 15 day of continuous oral consumption of same quantity of curcumin nanoparticles (white spots). The effect of curcumin and nanocurcumin was studied on the levels of serum SGPT, SGOT, ALP, albumin and bilirubin. Results of said tests are depicted in FIGS. 15 . 1 - 15 . 5 . It is apparent that SGOT and SGPT levels are not significantly altered and albumin levels are increased in naocurcumin treated group indicating that nanocurcumin is good for the liver. The ALP and Bilirubin levels were also in the normal range except in one or two cases showing that curcumin and nanocurcumin do not have any adverse effect on liver function.
EXAMPLE 16
Effect of Oral Intake of Curcumin and Nanocurcumin on Globulin Level, Eosinophils and Neutrophils Count and Platelet Count of Human Volunteers
[0139] Curcumin nanoparticles at a dose of 500 mg/day/person were given orally to nine human volunteers (1, 3, 4, 6, 8, 9, 10, 11 & 12) who gave their informed consent to participate in the study. Normal curcumin was given orally to another group of seven human volunteers (2, 5, 7, 13, 14, 15 & 16) at a dose of 500 mg/day/person. The level were measured before the start of the experiment (dark spots) and after 15 day of continuous oral consumption of same quantity of curcumin nanoparticles (white spots).
[0140] Results of said tests are depicted in FIGS. 16 . 1 - 16 . 4 . The result indicates that there is no significant effect of curcumin on the levels of eosinophiles, neutrophils and platles.
EXAMPLE 17
Anti-Malaria Effect of Nanocurcumin
[0141] Patients suffering from malaria were administered nanocurcumin capsules after having their informed consent under the supervision of a traditional medicine practitioner at a dose of 200 mg twice daily for 5 to 7 days for Plasmodium vivax cases and 200 mg four times per day for 5 to 7 days for Plasmodium falciparum cases. All nine patients were cured (table 4). Another group of five patients were studied for relapse. The patients who were cured did not show any relapse for at least 9 months. (table 5).
[0000]
TABLE 4
Details of Malaria Treatment with Nanocurcumin
Examined
Serial
Start of
for parasite
Remarks/
no
Age
sex
Diagnosis
Treatment
in the blood
relaps
1
11
F
Infected
15 Jul. 2009
20 Jul. 2009
Cured
with both
no parasite
Plasmodium
or parasite
vivax and
antigen
Plasmodium
detected
falciparum
2
45
M
Infected with
16 Jul. 2009
21 Jul. 2009
Cured
P.
falciparum
no parasite
or parasite
antigen
detected
3
29
M
Infected
10 Jul. 2009
15 Jul. 2009
Cured
with both
no parasite
P. vivax and
or parasite
P.
falciparum
antigen
detected
4
8
M
Infected with
10 Jul. 2009
15 Jul. 2009
Cured
P.
falciparum
no parasite
or parasite
antigen
detected
5
23
F
Infected with
12 Jul. 2009
17 Jul. 2009
Cured
P.
falciparum
no parasite
or parasite
antigen
detected
6
4
M
Infected with
13 Aug. 2009
21 Aug. 2009
Cured
P.
vivax
no parasite
or parasite
antigen
detected
7
12
M
Infected with
28 Aug. 2009
12 Sep. 2008
Cured
P.
vivax
no parasite
or parasite
antigen
detected
8
5
M
Infected with
1 Aug. 2009
12 Sep. 2008
Cured
P.
vivax
no parasite
or parasite
antigen
detected
9
19
M
Infected with
2 Sep. 2008
11 Sep. 2008
Cured
P,
vivax
no parasite
or parasite
antigen
detected
[0000]
TABLE 5
Details of Malaria Treatment and Realapse Studies in
patients treated with Nanocurcumin
Examined
for
Serial
Start of
parasite in
Remarks/
no
Age
sex
Diagnosis
Treatment
the blood
relaps
1
42
M
Infected with
4 Jul. 2008
12 Jul. 2008
No relapse
Plasmodium
reported
vivax
since 1 year
after cure
2
37
F
Infected with
9 Aug. 2008
30 Aug. 2008
No relapse
Plasmodium
reported
vivax
since
11 months
after cure
3
33
M
Infected with
8 Sep. 2008
20 Sep. 2008
No report
Plasmodium
of relapse
vivax
since
10 months
after cure
4
19
M
Infected with
10 Sep. 2008
20 Sep. 2008
No report
Plasmodium
of relapse
vivax
since
10 months
of cure
5
45
M
Infected with
10 Oct. 2008
25 Oct. 2008
No report
Plasmodium
of relapse
vivax
since
9 months
after cure. | 4y
|
BACKGROUND OF THE INVENTION
This invention relates generally to the cleaning of semiconductor materials and specifically to the post silica polish cleaning of semiconductor wafers.
With the advent of microminiaturization of electronic devices, the need for damage-free, smooth and clean semiconductor wafer surfaces has become increasingly important. Smooth, polished surfaces are obtained by the use of polishing slurries. Silica polishing is an example of a typical polishing process. In the silica polishing process, a polishing slurry is used which includes a colloidal silicon dioxide abrasive, sodium dichloroisocyanurate as an oxidizing agent, and sodium carbonate as a base. The pH of the polishing slurry is below 10. After polishing, it is necessary to clean the polished surface to remove the polishing slurry and other surface contaminants with a minimum of chemical or mechanical surface damage.
At the end of the silica polishing process, removal of the following materials from the wafer surface must be considered in order to produce a clean surface:
1. Colloidal silicon dioxide.
2. Sodium dichloro-isocyanurate and its reaction products with sodium carbonate.
3. Sodium carbonate.
4. Amorphous silicon dioxide.
5. Other metallic impurities deposited on silicon surfaces from slurry components.
Various mechanical and chemical processes have been used to clean silica or other metal oxide based slurry polished wafers. These processes either produce mechanical damage, change the surface characteristics significantly, or use chemicals which present environmental and/or hygienic considerations. Most of the chemical methods produce hydrophillic surfaces which are susceptible to reaction with atmospheric contaminants.
A new physico-chemical process has been found which results in a clean, hydrophobic semiconductor surface without damaging the surface.
BRIEF SUMMARY OF THE INVENTION
In accordance with this invention there is provided a method of removing colloidal silica from a semiconductor surface comprising treating the surface with an aqueous solution of a quarternary ammonium salt to coagulate and suspend the silica in the aqueous solution and removing the aqueous solution from the surface. The surface then can be further treated with NH 4 OH to remove any heavy metal contaminants.
DETAILED DESCRIPTION
The silicon dioxide based aqueous slurries used in polishing semiconductor surfaces include colloidal silicon as the abrasive material, an oxidizing agent such as sodium dichloroisocyanurate and a base such as sodium carbonate.
After Polishing with silicon dioxide slurries, the polished surface is normally hydrophobic. This is believed to be due to the condensation of adjacent surface hydroxyl groups to form a siloxane-type surface oxide layer. The surface is contaminated with colloidal SiO 2 , amorphous SiO 2 , sodium carbonate and polishing pad material. Water washing alone does not remove the contaminants. Oxidizing agent treatments such as NaClO followed by a NH 4 OH rinse produce a clean surface but chemically alter the surface by producing free hydroxyl groups which gives the surface a hydrophilic nature. Attempts to coagulate and remove the silica with electrolytes such as NaCl, although preserving the hydrophobic nature of the surface, are found to form a film on the surface which is believed to be SiO 2 .
A clean, film free, hydrophobic surface is obtained by the use of cationic surfactants which are quarternary ammonium salts. Such materials are represented by the formula ##STR1## where R 1 is a long chain alkyl group containing about 12 to 18 carbons
R 2 and R 3 and R 4 are lower alkyl and substituted lower alkyl groups and various combinations thereof such as methyl, ethyl, propyl, benzyl, etc., and
X - is an anion.
Preferred anions are halogens (Cl - , Br - , I - ) but other anions such as sulfate, methyl sulfate, phosphate, acetate, citrate, tartrate can be used.
Examples of such compounds are long chain alkyl (C 12 -C 18 mixed or pure) dimethyl benzyl ammonium chloride, cetyl dimethylethyl ammonium bromide, and cetyl trimethyl ammonium bromide.
A suitable minimum concentration of the quarternary ammonium salt in water is about 0.1 weight percent with about 0.5 weight percent being preferred. Greater amounts can be used effectively but as a practical matter are not necessary. After the polishing operation is completed, the polished semiconductor article is, without being allowed to dry, treated with the quarternary ammonium salt solution. A preferred treatment is to place the article in the solution at ambient temperature and allowing it to remain in the solution for several minutes. Stirring or other form of agitation aids the cleaning process.
The article is next rinsed with H 2 O and then, where heavy metal ion contamination may be present, with dilute NH 4 OH (about 3 to 5% by weight). The NH 4 OH rinse removes any heavy ion contamination without altering the hydrophobic nature of the semiconductor surface. A complexing agent could also be added to the NH 4 OH solution to aid in ion removal. The surface is then rinsed in water and can be brush cleaned with water.
The invention is further illustrated by, but is not intended to be limited to the following examples in which parts are parts by weight unless otherwise indicated.
EXAMPLE 1
Silicon wafers which were polished with a silica polishing slurry and then water rinsed are taken from the polishing machine and, without drying are placed into a 0.5% by weight solution of mixed alkyl (C 12 -C 18 ) dimethyl benzyl ammonium chlorides for 5 minutes. The mixture contained, by weight, 5% of material having a C 12 alkyl group; 60% having a C 14 alkyl group; 30% having a C 16 alkyl group and 50% having a C 18 alkyl group. The wafers are removed from solution and rinsed with deionized water and then treated in a spray of 3% by weight aqueous NH 4 OH for 30 seconds followed by a spray rinse with deionized water and spin drying in a hot nitrogen atmosphere. The entire rinsing process is performed in an automated Coretek spray dry machine taking a total of 5 minutes. The wafers are then brush cleaned using deionized water. The wafers are hydrophobic after the cleaning process (water beads on the surface). The wafer surfaces are clean and haze free. An emission spectrographic analysis of the cleaned wafers indicated negligible amounts of Al, Ca, Cr, Cu, Fe, Mg, Na and Ti.
EXAMPLE 2
The cleaning process of Example 1 was repeated using, in place of the mixed alkyl dimethyl benzyl ammonium chloride, either a 0.5% by weight solution of cetyl dimethylethyl ammonium bromide or a 0.5% by weight solution of cetyl trimethyl ammonium bromide. These solutions also gave clean hydrophobic haze free wafer surfaces.
The foregoing process provides polished semiconductor surfaces which are clean, haze free and hydrophobic. The surfaces are not degraded by the cleaning process and the process employs environmentally and hygenically acceptable materials.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. | 4y
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the analysis of statistical data, preferably on a computer and using a computer implemented program. The invention more specifically relates to a method and apparatus that accurately analyzes statistical data when that data is not “normally distributed,” by which is meant, as used herein, that the data set does not correspond to a “normal probability distribution” or does not show a bell-shaped curve.
2. Description of the Prior Art
Conventional data analysis involves the testing of statistical hypotheses for validation. The usual method for testing these hypotheses, in most situations, is based on the well known “General Linear Model,” which produces valid results only if the data are either normally distributed or approximately so.
Where the data set to be analyzed is not normally distributed, the known practice is to transform the data by non-linear transformation to comply with the assumptions of most statistical tests. This practice is disclosed in, for example, Haoglin, Mosteller, Tukey, U NDERSTANDING R OBUST AND E XPLORATORY D ATA A NALYSIS (1977), which is incorporated herein by reference. It was previously thought that data could be transformed to comply with known distributional assumptions without affecting the integrity of the analysis. More recent research has demonstrated, however, that the practice of non-linear transformation actually introduces unintended and significant error into the analysis. See, e.g., Terrence B. Peace, Ph.D, T RANSFORMATION AND C ORRELATION (2000) and T RANSFORMATION AND T-T EST (2000), which is incorporated herein by reference. A solution to this problem is needed. The subject invention therefore provides a method and apparatus capable of evaluating statistical data and outputting reliable analytical results without relying on transformation techniques.
U.S. Pat. No. 5,893,069 to White, Jr., entitled “System and method for testing prediction model,” discloses a computer implemented statistical analysis method to evaluate the efficacy of prediction models as compared to a “benchmark” model. White discloses the “bootstrap” method of statistical analysis in that it randomly generates data sets from the empirical data set itself.
SUMMARY OF THE INVENTION
It is therefore an object of the invention disclosed herein to provide a method and apparatus, preferably implemented on a computer and with appropriate software, which more accurately analyzes statistical data that is distributed non-normally.
It is another object of the instant invention to provide a computer and computer implemented method and program by which statistical data can be analyzed under virtually any distributional assumptions, including normality.
It is yet another object of the invention to analyze said data without transforming the naturally occurring distribution of the original data into a Normal distribution, thereby avoiding errors which transformation may introduce into the analysis, said transformation preceding traditional data analysis techniques.
It is another object of the invention to enable and otherwise enhance sensitivity analysis to cross-check results of the analysis.
It is a further object of the present invention to provide a method and apparatus for the analysis of statistical data for use in various disciplines which rely in whole or part on statistical data analysis and forecasts, including marketing, economics, materials, administration and medical research.
It is an additional object of the present invention to provide a method and apparatus of statistical analysis which enable the user to construct new test statistics, rather than rely on those test statistics with distributions that have already been determined. The subject invention removes this restriction so that any function of the data may be used as a test statistic.
It is a further object of the present invention to provide a method and apparatus for statistical analysis that enables the user to make inferences on multiple parameters simultaneously. The instant invention will permit all aspects of more than one distribution to be tested one against the other in a single analysis and determine significant differences, if any exist.
Yet another object of the present invention is to provide a method and apparatus that enables a user to perform sensitivity analysis on the inference procedure while using all of the underlying data.
These and other objects will become readily apparent to a person of skill in the art having regard for this disclosure.
The invention achieves the above objects by providing a technique to analyze empirical data within its original distribution rather than transforming it to a Normal distribution. It is preferably implemented using a digital processing computer, and therefore a computer, as well as a method and program to be executed by a digital processing computer. The technique comprises, in part, the computer generating numerous random data sets having the identical size and dimension as the original data set, with a distribution defined to best describe the process which generated the original data set. Functions of these randomly generated data sets are compared to a corresponding function of the original data set to determine the likelihood of such a value arising purely by chance. The best mode of the invention requires input from the user defining a number of options, although alternative modes of the invention would involve the computer determining options at predetermined stages in the analysis. The method and program disclosed herein is superior to prior art in that it allows data to be analyzed more accurately, permits the data to be analyzed in accordance with any distribution (including the distribution which generated the data), avoids the errors which may be introduced by data transformation, and facilitates sensitivity analysis.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated in the figures of the accompanying drawings, which are meant to be exemplary and not limiting:
FIG. 1 is a schematic diagram of the hypothesis testing evaluation system.
FIG. 2 a and FIG. 2 b depict a flow chart showing the steps for executing the hypothesis testing method and program.
FIG. 3 is a flow chart showing of the steps for executing the hypothesis testing method and program in which the hypothesis is replaced by a confidence interval.
DETAILED DESCRIPTION OF INVENTION
As discussed above, the present invention supplies a computer and appropriate software or programming that more accurately analyzes statistical data when that data is not “normally distributed.” The invention therefore provides a method and apparatus for evaluating statistical data and outputting reliable analytical results without relying on traditional prior art transformation techniques, which introduce error. The practice of the present invention results in several unexpectedly superior benefits over the prior art statistical analyses.
First, it enables the user to construct new and possibly more revealing test statistics, rather than relying on those test statistics with distributions that have already been determined. For example, the “t-statistic” is often used to test whether two samples have the same mean. The numerical value of the t-statistic is calculated and then related to tables that had been prepared using a knowledge of the distribution of this test statistic. Prior to the subject invention, a test statistic has been useless until its distribution has been discovered; thus, for all practical purposes, the number of potential test statistics has been relatively small. The subject invention removes this restriction; any function of the data may be used as a test statistic.
Second, the invention enables the user to make inferences on multiple parameters simultaneously. For example, suppose that the null hypothesis (to be disproved) is that two distributions arising from two potentially related conditions are the same. Traditional data analysis might reveal that the two means are not quite significantly different, nor are the two variances. The result is therefore inconclusive; no formal test exists within the general linear model to determine if the two distributions are different and that this difference is statistically significant. The present inventions will permit all aspects of both distributions to be tested one against the other in a single analysis and determine significant differences, if any exist.
Third, sensitivity analysis is a natural extension of the data analysis under the invention, whereas sensitivity analysis is extremely difficult and impractical using current methods and software. Sensitivity analysis examines the effect on conclusions of small changes in the assumptions. For example, if the assumption is that the process that generated the data is distributed as Beta ( 2 , 4 ), then a repeat analysis under a slightly different assumption (e.g. Beta ( 2 , 5 )) should not produce a markedly different result. If it does, conclusions obtained from the initial assumption should be treated with caution. Such sensitivity analysis under the invention is simple and is suggested by the method itself.
U.S. Pat. No. 5,893,069 to White discloses a computer implemented statistical analysis method to evaluate the efficacy of prediction models as compared to a “benchmark” model. However, the invention disclosed herein is superior to this prior art in that it tests the null hypothesis against entirely independent, randomly-generated data sets having the identical size and dimension as the original data set, with a distribution defined to best describe the process which generated the original data set under the null hypothesis.
The present invention is remarkably superior to that of White, in that the present invention enables the evaluation of an empirically determined test statistic by comparison to an unadulterated, randomly produced vector of values of that test statistic. Under the disclosed invention, when the empirical test statistic falls within an extreme random-data-based range of values (e.g. above the 95 th percentile or below the 5 th percentile), the null hypothesis which is being tested can be rejected as false, with a high level of confidence that is not merited in the prior art with respect to non-normal data distributions. Therefore, the ability is greatly enhanced to determine accurately whether certain factors are significantly interrelated or whether certain populations are significantly different.
Statistical hypothesis testing is the basis of much statistical inference, including determining the statistical significance of regression coefficients and of a difference in the means. A number of important problems in statistics can be reduced to problems in hypothesis testing, which can be analyzed using the disclosed invention. One example is determining the likelihood ratio L, which itself is an example of a test statistic. When formulated so that the likelihood ratio is less than one, then the null hypothesis is rejected when the likelihood ratio is less than some predetermined constant k. When the constant k is weighted by the so-called prior probabilities of Bayes Theory, the disclosed invention encompasses Bayesian analyses as well. As related to the disclosed invention, the likelihood ratio may be generalized so that different theoretical distributions are used in the numerator and denominator.
Also, the likelihood ratio or its generalization may be invoked repeatedly to solve a multiple decision problem, in which more than two hypotheses are being tested. For example, in the case of testing an experimental medical treatment, the standard treatment would be abandoned only if the new treatment were notably better. The statistical analysis would therefore produce three relevant possibilities: an experimental treatment that is much worse, much better or about the same as the standard treatment, only one of which would result in rejection of the standard treatment. These types of multiple decision problems may be solved using the disclosed invention by the repeated use of the likelihood ratio as the test statistic.
Prediction problems may also be analyzed, whether predicting future events from past observations of the same events (e.g. time series analysis), or predicting the value of one variable from observed values of other variables (e.g. regression). The significance of the statistical model's performance, meaning the likelihood that the model would predict to the same level of accuracy due only to chance, may also be estimated. The method and program disclosed may also be used in this case and, in most practical situations, will prove to be superior.
The instant invention may also be used to determine confidence intervals, which is a closely related statistical device. Whereas hypothesis testing begins with the numerical value of the test statistic and derives the respective probability, a confidence interval begins with a range of probabilities and derives a range of possible test statistics. A common confidence interval is the 95 percent confidence interval, and ranges between the two percentiles P2.5 and P97.5. Given the symmetrical relation of the two techniques, there would be nearly identical methods of calculation. A slight modification of the disclosed method, which is obvious to those skilled in the art, enables the user to construct confidence intervals as opposed to test hypotheses, with a greater level of accuracy.
Thus, this invention relates to determining the likelihood of a statistical observation given particular statistical requirements. It can be used to determine the efficacy of statistical prediction models, the statistical significance of hypotheses, and the best of several hypotheses under the multiple decision paradigm, as well as to construct confidence intervals, all without first transforming the data into a “normal” distribution. It is most preferably embodied on a computer, and is a method to be implemented by computer and a computer program that accomplishes the steps necessary for statistical analysis. Incorporation of a computer system is most preferred to enable the invention.
Referring to FIG. 1 , the computer system includes a digital processing apparatus, such as a computer or central processing unit 1 , capable of executing the various steps of the method and program. In the preferred embodiment, the computer 1 is a personal computer known to those skilled in the art, such as those manufactured by IBM, Dell Computer Corporation, Hewlett Packard and Apple. Any corresponding operating system may be involved, such as those sold under the trademark “Windows.” Other embodiments include networked computers, notebook computers, handheld computing devices and any other microprocessor-driven device capable of executing the step disclosed herein.
As shown in FIG. 1 , the computer includes the set of computer-executable instructions 2 , in computer readable code, that encompass the method or program disclosed herein. The instructions may be stored and accessible internally to the computer, such as in the computer's RAM, conventional hard disk drive, or any other executable data storage medium. Alternatively, the instructions may be contained in an external data storage device 3 compatible with a computer readable medium, such as a floppy diskette 9 , magnetic tape or compact disk, compatible with and executable by the computer 1 .
The system can include peripheral computer equipment known in the art, including output devices, such as a video monitor 4 and printer 5 , and input devices, such as a keyboard 6 and a mouse 7 . Embodiments of the invention contemplate any peripheral equipment available to the art. Additional potential output devices include other computers, audio and visual equipment and mechanical apparatus. Additional potential input devices include scanners, facsimile devices, trackballs, keypads, touch screens and voice recognition devices.
The computer executable instructions 2 begin by defining the structure of data set 11 of FIG. 2 , a flowchart of the computer executable steps. The original data to be analyzed is collected into the data set 12 . This original data introduced at step 12 may consist of known empirical data; theoretical, hypothetical or other synthetically generated data; or any combination thereof. The original data set 12 is stored as a computer accessible database 8 of FIG. 1 . The database 8 can be internal to or remote from the computer 1 . The database 8 can be input onto the computer accessible medium in any fashion desired by the user, including manually typing, scanning or otherwise downloading the database.
Referring to FIG. 2 , the user specifies a test statistic 13 and formal hypothesis 14 in terms of said test statistic, in most practical cases known as the null hypothesis, concerning data set 12 . The term test statistic is used to denote a function of the data that will be used to test the hypothesis. The terms “numerical value of the test statistic” and “numerical test statistic” denote a particular value calculated by using that function on a given data set. Determination of a test statistic may be accomplished by known means. See, for example, in P. G. Hoel, S. C. Port & C. J. Stone, I NTRODUCTION TO S TATISTICAL T HEORY (1971), which is incorporated herein by reference. Examples of test statistics include a two sample t-statistic, which approximates the “Student's t-distribution” under fairly general assumptions, the Pearson product-moment correlation coefficient r, and the likelihood ratio L. Embodiments of the invention would include computing the numerical values of several test statistics simultaneously, in order to test compound hypotheses or to test several independent hypotheses at the same time.
Embodiments of the invention may include the realm of test statistics known in the art to be previously input to the computer and stored in computer accessible database 2 , either internal to or remote from the computer 1 . Specifying a test statistic 13 of FIG. 2 may then be accomplished by the user, when prompted in the course of program execution, selecting from the test statistic database. Likewise, the computer 1 may include executable instructions to select the test statistic 13 from the database of test statistics. It is also contemplated that the user might define their own test statistic.
The hypothesis 14 , specified in terms of said test statistic 13 , may take several forms. Embodiments of this invention encompass any form of statistical problem that can be defined in terms of a hypothesis. In the preferred embodiment of the invention, the formal hypothesis 14 would be a “null hypothesis” addressing, for example, the degree to which two variables represented in the original data set 12 are interrelated or the degree to which two variables have different means. However, the formal hypothesis 14 may also take any form alternative to a null hypothesis.
For example, the hypothesis may be a general hypothesis arising from a multiple decision problem, which results in the original data falling within one of three alternative possibilities. Regardless of the form, the hypothesis represents the intended practical application of the computer and computer executable program, including testing the validity of prediction models and comparing results of experimental versus conventional medical treatments.
Using the original data set 12 , the computer determines a numerical value NTS of the test statistic 13 from the data set, as indicated in block 15 of FIG. 2 . Confidence intervals may also be constructed by a similar technique embodied by this invention, as indicated in FIG. 3 . The primary difference between FIG. 2 and FIG. 3 relate to the interchanged roles of test statistic and probability: In hypothesis testing the probability is derived from the test statistic, while in confidence interval determination, a range of test statistics is derived from probabilities. Otherwise, the basic underlying novel concept is the same.
The disclosed invention may be seen more clearly by reference to block 16 of FIG. 2 (and block 45 of FIG. 3 ). In the preferred embodiment, the user specifies the probability distribution in block 16 that describes the original data set 12 under the null hypothesis 14 . This distribution is the one from which the user theorizes the data may have arisen under the hypothesis 14 . Conventional data analysis usually specifies the normal probability distribution, but under the disclosed invention, any distribution of data may be used to test hypothesis 14 . One may appropriately specify the probability distribution from various considerations, such as theory, prior experimentation, the shape of the data's marginal distributions, intuition, or any combination thereof. The types and application of common probability distributions of statistical data sets are set forth and described in detail in various texts, including by way of example N. L. Johnson & S. Kotz, D ISTRIBUTIONS IN S TATISTICS , Vols. 1-3 (1970), which is incorporated herein by reference.
Embodiments of the invention include the realm of statistical distributions known in the art to be previously input to the computer and stored in computer accessible data set 8 of FIG. 1 , either internal to or remote from the computer 1 . The step in block 16 of specifying a distribution may then be performed by the computer based on its analysis of the original data set 12 . In the alternative, the user may specify the distribution by selecting from among the previously stored database of options, or defining any other distribution, including those not previously studied.
As shown in the next block 17 of FIG. 2 , the number of iterations N to be performed by the computer in analyzing the hypothesis 14 is specified. This is an integer that, in the preferred embodiment, would be no less than 1,000. The invention contemplates any number of iterations, the general rule being that the accuracy of testing the hypothesis 14 increases with the number of iterations N. Factors affecting determination of N include the capabilities of computer 1 , including processor speed and memory capacity. The computer then initializes variable i, setting it to zero in step 18 . This variable will correspond to each randomly produced data set performed in subsequent steps.
In the preferred embodiment, beginning at block 19 , the computer then enters a repetitive loop of generating data for purposes of comparing and analyzing the original data set 12 . The loop begins on each iteration with incrementing integer i by one. The computer then generates a set of random data RDS(i) at block 20 having the identical size and dimension as the original data set 12 , with a distribution defined to best describe the process which generated the original data set under the null hypothesis 14 . (More succinctly, the random data set will be described as having “the same size, dimension and distribution as the original data set 12 .”) The computer may generate the random data using any technique known to the art that approximates truly random results. The preferred embodiment incorporates the so-called M onte C arlo technique, which is described in the published text G. S. Fishman, M ONTE C ARLO —C ONCEPTS , A LGORITHMS AND A PPLICATIONS (1995), which is incorporated herein by reference.
Using this randomly generated data set, the computer determines at block 21 a corresponding numerical value TS(i) of the test statistic, which is one example of a test statistic value that might arise at random under the null hypothesis 14 , distributed as distribution 16 . This numerical value is stored in a numerical test statistic array 22 .
At decision diamond 23 , the computer compares i with the value N to determine whether they are yet equal to one another. If i is still less than N, the computer returns to the beginning of the repetitive loop as shown in block 24 and increments variable i by one at block 19 . The computer then generates another set of random data RDS(i) at block 20 of the same size, dimension and distribution as the original data set 12 . Using this randomly generated data set, the computer again determines at block 21 a corresponding numerical value TS(i) of the test statistic and stores TS(i) in the numerical test statistic array 22 . This process is repeated until the computer determines that i equals N at the conclusion of the repetitive loop at decisional diamond 23 . At that time, the computer will have stored an array consisting of N numerical values of test statistics derived from randomly generated data sets.
After the computer has stored an array of randomly generated numerical test statistics, it must determine where among them falls the numerical test statistic NTS corresponding to the original data set 12 . In this process, the value of the data dependent statistic, e.g. the median or 50 th percentile, will be referred to as the “percentile value P” and the ordinal number that defines the percentile, e.g. the 95 th in 95 th percentile, will be referred to as the “percentile index p.” More specifically, the computer must determine a percentile value P corresponding to NTS, so that the percentile index p may be determined. This percentile index p may then be used to infer the likelihood that the value of NTS arose by chance, which is the statistical significance of NTS.
The invention includes any manner of relating NTS with a percentile value P based on the numerical test statistic array of randomly generated results. However, a preferred embodiment of the invention is shown in blocks 25 through 33 of FIG. 2 . The preferred embodiment technique begins with initializing variable j to one at block 25 . The computer then sorts the numerical test statistic array into ascending order at block 26 , resulting in an ordered array OTS having the same dimensions and containing the same data as the test statistic array of step 22 . However, with the array arranged in an incrementally sorted format, the computer is able to systematically compare the original numerical test statistic NTS with the randomly based numbers to determine its corresponding percentile value P and associated percentile index p.
This systematic comparison begins at decision diamond 27 , which first compares the numerical value NTS with the smallest numerical value in the array of stored numerical test statistics, defined as OTS(1). If NTS is less than OTS(1), then it is known that NTS is smaller than the entire set of numerical test statistics corresponding to randomly generated data sets of the same size, dimension and distribution as the original data set 12 . The computer determines that NTS is in the “zeroth” percentile, indicating that the original numerical test statistic NTS is an extreme data point beyond the bounds of the randomly generated values and, therefore that the chances of the event happening by chance under a two-tailed null hypothesis are very remote. The conclusion of the computerized evaluation therefore may be to reject the null hypothesis or to re-execute the program using a higher value N to potentially expand the randomly generated comparison set.
The computer outputs its results as shown in block 28 , which would include the percentile index zero of the original numerical test statistic NTS. The invention contemplates any variation of data output at the final step, in any form compatible with the computer system. A preferred embodiment is an output to a monitor 4 or printer 5 of FIG. 1 that identifies the numerical value of the test statistic NTS derived from the original data set 12 , the corresponding percentile index p relating to the likelihood of NTS arising by chance, and the number of random data sets N on which p is based. In this case of NTS being less than all randomly based test statistics, p would equal zero. This raw percentile value may also be interpreted in terms of the null hypothesis 14 ; in the case of a two-tailed test, such an extreme value would lead to rejecting the null hypothesis, while in a one-tailed test this could lead to accepting the null hypothesis.
If at decision diamond 27 the computer determines that OTS( 1 ) is not greater than NTS, it moves to decision diamond 29 , which tests the other extreme. In other words, the computer determines whether NTS is larger than the highest value OTS(N) of the numerical test statistics corresponding to randomly generated data sets having the same size and dimension as the original data set 12 . If the answer is yes, then the computer determines that NTS is in the “one hundredth” percentile, usually indicating that the null hypothesis should be rejected because the test statistic is statistically significant (i.e. not likely to have resulted from chance). The results are then output as described above and as provided in block 28 of FIG. 2 .
If NTS does not fall beyond either extreme, the computer moves, to a repetitive loop, consisting of steps 31 through 33 , which brackets NTS between two numerical test statistics arising from randomly generated data. First, the variable j is incremented by 1 at block 31 . Then, at decision diamond 32 , the computer determines whether the numerical value OTS(j) is larger than the numerical value NTS. If not, the computer returns to the beginning of the loop at block 31 , as indicated by block 33 , increments j by one, and again compares the numerical value OTS(j) with NTS. This process is repeated until OTS(j) is larger than NTS, which means that NTS falls between OTS(j) and OTS(j−1). The percentile value P and associated percentile index p therefore correspond to this positioning of NTS on the ordered array OTS of test statistics corresponding to randomly generated data sets. Once these bracketing values are known, the computer proceeds to output the results.
The output of a preferred embodiment will be a function of percentile indices. The percentile indices corresponding to the percentile values which bracket NTS are described as being between (j−1)/N×100 percent and j/N×100 percent. For example, if the repetitive loop of blocks 31 through 33 determines that OTS(950) out of a set of 1000 numerical test statistics arising from respective randomly generated data sets is the lowest value of OTS(j) higher than NTS, then the value of NTS lies between the percentile values with indices 949/1000×100% and 950/1000×100%, or indices 94.9% and 95.0%, which allows the conclusion that 94.9%<P<95.0%, where P in this case refers to the probability rather than the percentile, although of course the two are closely related. Probability P is estimated by the percentile indices. As described above, this information regarding the value of probability P is output from the computer among other relevant data as shown in block 28 .
The output probability P estimates the likelihood that the original numerical value of the test statistic might have arisen from random processes alone. In other words, the computer determines the “significance” of the original numerical test statistic NTS. For example, if the computer determines that NTS is within the 96 th percentile among the numerical ordered test statistic array OTS, it may be safe to conclude that it did not occur by chance, but rather has statistical significance in a one-tailed test (i.e. it is significant at the 4 percent level). Based on this information, the original hypothesis 14 , whether it refers to a prediction model or a relationship between two variables represented in the original data set 12 , may be rejected.
FIG. 3 shows a related embodiment using the same theory regarding generation of random data sets of the same size and dimension as the original data set 41 , and distributed according to the specified distribution 45 . Although the term “test statistic” is usually associated with hypothesis testing, this term will be retained in the discussion of confidence intervals in order to emphasize the essential similarity of the two procedures. As before, the term “test statistic” will be used to denote some function of the data to be found in the data set, e.g. arithmetic mean, and will be used to subsume terms such as “estimator” and “decision function.” The initialization is identical as that shown in FIG. 2 , except instead of specifying a null hypothesis at block 14 , the user specifies the size of the confidence interval at block 43 , having ends of the interval defined as “Lo” and “Hi.” As a practical matter, the confidence interval specified at this step usually would be symmetrical of size 95 percent. This means that, in this mode, the disclosed invention will identify the two values of the test statistic between which the observed numerical value NTS of the test statistic is 95 percent likely to occur. The corresponding value of “Lo” is 0.025 and the corresponding value of “Hi” is 0.975 (which defines an interval of size 0.950, or a 95 percent interval).
After the confidence interval is specified, the disclosed invention continues as shown in FIG. 2 and described above. The numerical value of the test statistic is calculated at block 44 , the distribution is specified in block 45 , the number of iterations is specified at block 46 and an array of random data sets and the array of corresponding numerical values of the test statistic are generated in the repetitive loop of blocks 48 to 53 . In a preferred embodiment, the numerical statistic array is then sorted at block 54 into ascending order to accommodate analysis of the numerical value of the statistic specified in block 42 and calculated in block 44 .
Hereafter, the process is customized to the extent necessary to format usable and appropriate output from the computer. Blocks 55 through 58 determine the numerical values defining the high and low endpoints of the desired confidence intervals. At blocks 55 and 56 , the computer determines which two values of OS to use in calculating the lower limit of the confidence interval, by multiplying Lo by N and identifying the greatest integer less than or equal to that product. That integer and its successor are used to identify the required values of OS. Assuming that N was specified as 1000, with a symmetric 95 percent confidence interval, in the preferred embodiment, the values of OS would be 0.025×1000=25, and the next higher value, 26. The lower endpoint of the confidence interval would be given by a function f of these two OS values, f(OS(25), OS(26)).
Similarly, at blocks 57 and 58 , the computer determines which two values of OS to use in calculating the upper limit of the confidence interval, by multiplying Hi by N and identifying the smallest integer greater than or equal to that product. That integer and its successor are used to identify the required values of OS. Again assuming N is equal to 1000 and the confidence interval is symmetrical, in the preferred embodiment, the values of OS would be 0.975×1000, and its successor, 976. The upper endpoint of the confidence interval would be given by a function g of these two OS values, g(OS(975), OS(976)). Note that the functions f and g will depend on the current statistical practice and the philosophy the developer, but will typically be functions such as maximum, minimum, or linear combination. The final step of the confidence interval analysis is to output the relevant data, as shown in block 59 .
While the invention as herein described is fully capable of attaining the above-described objects, it is to be understood that it is the preferred embodiment of the present invention and is thus representative of the subject matter which is broadly contemplated, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims. | 4y
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