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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation application of Ser. No. 09/974,199 filed Oct. 10, 2001 now abandoned, which is a continuation-in-part application of Ser. No. 09/311,401 filed May 13, 1999 now abandoned.
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates generally to the manufacturing of steel in a furnace and more particularly to the manufacturing of steel from scrap metal in an electric arc furnace using scrap automotive tires as an auxiliary heat supplying source.
2. Description of the Prior Art
Scrap automotive tires present an environmental problem and recycling is practically nonexistent. Tires do not degrade in landfills and when stockpiled, create a major fire hazard that is impossible to extinguish once ignited. Since they have about the same heating value as coke, 15,000 BTU's per pound, a tire weighing about 20 pounds has approximately 300,000 BTU's. The scrap automotive tires are so plentiful that they have a near zero cost. At the present time, scrap automotive tires are being used as fuel or auxiliary fuel in a variety of operations such as cement kilns, coal fired generators and other applications wherein a controlled firing rate is used. In such instances, it is often necessary to shred the scrap automotive tires prior to using in a furnace. Also, when the scrap automotive tires contain steel belts, it is often necessary to remove the steel belts. In some instances whole rubber tires have been used but such use required equipment changes that reduced the cost advantages. In the manufacturing of steel from scrap metal, some of the steel mills add coke or coal to the scrap metal that is melted in a furnace such as an electric arc furnace.
An Electric Arc Furnace (EAF) is not an ordinary furnace in any sense of the word. It is a vessel for melting steel and providing metallurgical processing. It is believed that the EAF is the best choice for use of the tires, or as it is often referred to, tire derived fuel (“TDF”), as it can overcome all of the specific problems associated with the steel belts and beads when using TDF.
Tires are sometimes used as a fuel or supplemental fuel in the generation of electric power. Because of the problems created by the steel in the TDF they are not widely used or accepted as a fuel by electric utilities. Whether or not tires are used, the electric power has to be converted to higher voltages, transmitted to the steel mill and then converted back into heat by the electric arc. By using tires directly as energy in the steel furnace all of the losses in transmission and conversion are eliminated.
Because of the problems created by the steel belts and beads, the amount of tires now being used is not large enough to consume the amount of tires generated each year as scrap. TDF is the largest use for scrap tire disposal but the amount of tires scraped each year far exceeds the number that can be consumed by all of the various outlets combined. A large portion are shredded and buried in landfills. Only the steel industry, as a very large consumer of energy, has the capability to consume tires in an amount approaching that of the rate of disposal. Therefore, it should be noted that not only does the burning of tires for fuel increase the efficiency of the EAF, it also provides a unique solution for disposing of tires in an environmentally sound method. It provides an alternative to wasting and squandering valuable energy at a time when energy is becoming more scarce and costly. Furthermore, even when the steel industry decides to reuse the steel belts from the tires, the tires are stripped or shredded to remove the rubber to access the steel belts. Much of the rubber is then discarded, which provides only a limited solution to the problem of the waste rubber. There is therefore a need for a process which will utilize both the steel and the rubber found in most tires, and which does so in an efficient and productive manner.
In the EAF, coal or coke is added to the scrap charge as a source of chemical energy but also as an additional source of carbon for the steel being manufactured. The addition of rubber reduces or eliminates the need for coal or coke as a carbon source for steel chemistry requirements.
Therefore, an object of the present invention is to provide an improved method of melting scrap metal using scrap rubber.
Another object of the present invention is to provide an improved method of melting scrap metal using scrap rubber which includes the steps of combining a quantity comprising scrap metal containing steel and at least about 0.25 percent by weight of scrap rubber, forming a bundle of the combined scrap metal and scrap rubber, placing the bundle in an electric arc furnace and applying energy to the quantity in the furnace to start the combustion of the scrap rubber to add additional heat for melting the scrap metal containing steel.
Another object of the present invention is to provide an improved method of melting scrap metal using scrap rubber which will use various types of scrap rubber, including chopped, shredded and even whole tires baled and unbaled, both with the steel belt included and without.
Another object of the present invention is to provide an improved method of melting scrap metal using scrap rubber in which the pollution emitted from the steel plant is greatly reduced, because, specifically, when scrap rubber tires are added to the melting steel, the carbon monoxide emissions that normally occur from the arc furnace are greatly reduced.
Another object of the present invention is to provide an improved method of melting scrap metal using scrap rubber which includes a separate burning container for the tires which is in fluid transmission connection with the furnace such that the heat produced by the burning tires in the container is transferable to the furnace without adding impurities caused by the introduction of steel belts from the tires.
Finally, an object of the present invention is to provide an improved method of melting scrap metal using scrap rubber which is safe, efficient and environmentally sound in use.
SUMMARY OF THE INVENTION
This invention relates to a method for melting steel using scrap metal and at least about 0.25 percent by weight of scrap rubber, such as scrap automotive tires, wherein scrap metal and scrap rubber tires are deposited in a steel melting furnace, such as an electric arc furnace, and the scrap rubber tires or pieces thereof are combusted with air or oxygen to provide an auxiliary source of heat to melt the scrap metal.
In the preferred embodiment of the invention, an electric arc furnace is used. In the preferred method, a quantity of scrap metal with or without rubber is deposited in the electric arc furnace and heat is applied thereto to form a molten pool of metal. The scrap metal is the conventional scrap metal used to make steel. A quantity of scrap rubber, preferably scrap rubber tires, in an amount of at least 0.25 percent by weight, is then loaded into a bottom opening bucket and another quantity of scrap metal is loaded into the bucket on top of the scrap rubber tires. The bottom of the bucket is then opened and the scrap rubber tires fall into the electric arc furnace followed by the scrap metal. If desired, some of the scrap rubber tires could be included in the first quantity of scrap metal melted in the furnace. In addition to the electrodes, the furnace may have oxygen/air blow pipes or oxygen/natural gas burners to assist in the melting of the scrap metal and in the combustion of the scrap rubber tires. The scrap rubber tires ignite and are combusted to add auxiliary heat to the furnace. Once the scrap rubber tires are ignited, the natural gas is turned off and the oxygen is available for the combustion of the scrap rubber tires. The electrodes in the electric arc furnace continue to operate and function to control the temperature in the furnace. Additional charges of scrap metal or scrap metal and scrap rubber are subsequently added into the furnace until its capacity has been reached. Of course, the temperature in the furnace would preferably be the temperature normally used in the making of steel from scrap metal which is about 2950 degrees Fahrenheit.
In another preferred embodiment of the invention, a container for the pyrolysis of the scrap whole, or cut, or shredded and de-wired rubber tires is located adjacent to an electric arc furnace. Hot exhaust gases from the electric arc furnace are fed into a jacket surrounding the container to heat the whole, cut or shredded and de-wired rubber tires and convert them to combustible liquids and gases. Suitable control means are provided to feed the resulting combustibles into the electric arc furnace to function as an auxiliary source of heat during the combustion thereof.
In still another embodiment of the present invention, the scrap metal and scrap rubber are combined to form a scrap metal and rubber bundle, with the scrap rubber intermixed with the scrap metal. The metal acts as a flame retardant and also as a heat sink, thereby preventing rapid and uncontrolled burning of the scrap rubber. Further, the bundles may be picked up by a scrap magnet much as is done with the standard scrap metal bundles found in the industry today. The scrap metal/scrap rubber bundle thus provides a controlled rate of burning while also permitting relatively easy handling of the scrap rubber and scrap metal.
In yet another embodiment, the shredded rubber is added and intermixed with the shredded steel scrap to form a generally homogenous mixture. This mixture can then be readily handled by a magnet for easy insertion of the mixture into the EAF. It is thus seen that the present invention provides a substantial improvement over the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of apparatus for use in one preferred embodiment of the invention.
FIG. 2 is a schematic illustration of apparatus for use in another preferred embodiment of the invention.
FIG. 3 is a schematic illustration of apparatus for use in yet another preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is shown best in FIG. 1 , which illustrates an electric arc furnace 2 of the type generally used in a manufacturing operation to convert scrap metal into steel and is provided with a pouring spout 4 , bottom tap (not shown) or the like. The roof 6 with the electrodes 8 has been raised and swung aside. A charging bucket 10 having bottom doors 12 has been positioned over the electric arc furnace 2 and is supported by a pair of hooks 14 (only one shown) engaging outward projecting integral studs 16 (only one shown). The hooks 14 are part of a conventional crane (not shown) which moves the charging bucket 10 to the position over the electric arc furnace. Oxygen/natural gas burners 18 extend through the sidewall or roof of the electric arc furnace and are used to assist in the melting of the scrap metal and the ignition of scrap rubber tires as described below. Once the scrap rubber tires have been ignited, the natural gas is turned off and the oxygen is available for the combustion of the scrap rubber tires.
It is to be understood that although the present invention is described as using a charging bucket to add the scrap metal and rubber, more modern plants may add the scrap metal to the arc furnace via conveyors or shafts which permit the furnace to remain closed during the adding of scrap metal. The scrap rubber would be added to the conveyor or shaft in the desired amounts and at the proper time and location to enable the method of the present invention to be employed.
In a preferred process of this invention, a first quantity of scrap metal (not shown) of the type conventionally used in the manufacture of steel from scrap metal has been loaded into the charging bucket 10 and moved to the position illustrated in FIG. 1 . A quantity of scrap rubber tires is also placed in the charging bucket 10 and the scrap metal and rubber is then dropped into the electric arc furnace 2 . The charging bucket 10 is then removed and the roof 6 with the electrodes 8 mounted thereon is moved to an operating position in the electric arc furnace 2 . An electric current is supplied to the electrodes 8 and the oxygen/natural gas burners 18 are ignited to generate heat to melt the scrap metal. In one example of the process using an electric arc furnace having a capacity of 100,000 pounds, the first quantity of scrap metal comprised 30,000 pounds and the first quantity of scrap rubber comprised approximately 1,000 pounds.
During the melting of the first quantity of scrap metal, the charging bucket 10 is loaded with a second quantity of materials. The second quantity of materials comprises a quantity of scrap rubber tires which are first loaded into the charging bucket and a second quantity of scrap metal that is loaded into the charging bucket on top of the scrap rubber tires. It is important to note that various forms of scrap rubber tires can be used with the method of the present invention, including chopped, shredded, whole tires and even tire bales, both with the scrap steel included and without. It has been found that depending upon the desired rate of burn (infusion of energy from the burning tires), the size and amount of the scrap tire pieces can be modified and changed, with the quickest heat addition coming when shredded tires are used and the longest lasting heat addition coming when whole tires are used. The heat influx provided by the tires can be calculated such that a practitioner of the present invention would be able to generally control the amount and timing of heat influx, which is critical in the operation of the EAF and in the creation of certain alloys and other metal combinations.
After the charging bucket is filled with the scrap rubber tires and the scrap metal, the roof 6 with the electrodes 8 is raised and swung aside. The charging bucket 10 is moved to a position over the electric arc furnace 2 and the bottom doors 12 are opened to drop the scrap rubber tires followed by the additional scrap metal into the electric are furnace 2 . The charging bucket is moved out of the way and the roof 6 with the electrodes 8 is moved back onto the electric arc furnace 2 . The heat of the molten scrap metal in the electric arc furnace 2 and the heat generated by the electrodes 8 together with the oxygen/natural gas burners 18 in the furnace function to ignite the scrap rubber tires and their combustion with air or oxygen functions to produce auxiliary heat to heat the additional scrap metal as the heat moves through the additional scrap metal. The electrodes 8 continue to operate to control the temperature of the molten material and to assist in the melting of the additional scrap metal but the power supplied to the electrodes 8 is reduced as a result of the heat generated by the combustion of the scrap rubber tires. As stated above, once the scrap rubber tires have been ignited, the natural gas is turned off and the oxygen is available for the combustion of the scrap rubber tires. If the electric arc furnace 2 is not equipped with oxygen/natural gas burners, a conventional lance or blow pipe may be used to provide the oxygen for the combustion of the scrap rubber tires, in addition to other methods such as the admission of air into the furnace through doors, dampers or other such openings. In accordance with the example described above, the second quantity of materials comprises about 600 pounds of scrap rubber tires and about 30,000 pounds of additional scrap metal. The temperature in the electric arc furnace is the conventional temperature used to melt scrap metal which is about 2950 degrees Fahrenheit. If desired, a quantity of the scrap rubber tires, such as about 100 to 1000 pounds, can be included with the first quantity of scrap metal. During the melting of the second quantity of scrap metal, a second quantity of materials comprising a second quantity of scrap rubber tires and a third quantity of scrap metal is loaded into the charging bucket 10 . When the second quantity of scrap metal has been melted, the roof 6 with the electrodes 8 and the charging bucket 10 are moved to drop the third quantity of scrap metal into the electric arc furnace 2 , the charging bucket 10 is moved away and the roof 6 with the electrodes 8 are moved back into the operating position. In accordance with the example described above, the second quantity of scrap rubber tires is about 500 pounds and the third quantity of scrap metal is about 20,000 pounds.
The process is then repeated to add a third quantity of materials comprising a third quantity of scrap rubber tires and a fourth quantity of scrap metal necessary to reach the capacity of the electric arc furnace 2 . If the scrap rubber tires have steel belts, then the steel in the steel belts becomes part of the molten steel in the electric arc furnace 2 . The third quantity of scrap rubber tires is in an amount of about 500 pounds.
In the example described above, the second quantity of materials was added to the electric arc furnace 2 about 15 minutes after the current was supplied to the electrodes to commence the melting of the first quantity of scrap metal. The third and fourth quantities of materials are added in successive intervals spaced about 15 minutes apart. After about another 15 minutes, normal refining processes are performed on the molten metal to obtain desired characteristics. It is to be understood that the foregoing is only an example and that other quantities and ratios of scrap metal and scrap tires and other sizes of furnaces may be used.
While it may be preferable in general melting processes to use whole scrap rubber tires so as to control the combustion thereof, if shredded scrap rubber tire were to be used, the combustion would occur very rapidly and generate an amount of heat far greater than that produced by the combustion of the whole scrap rubber tires. A variation for additional control of combustion is shown in FIG. 3 in which scrap metal and scrap tire bundles 50 are dropped into a furnace 40 through an optimally located opening 46 , the furnace 40 already containing a quantity of molten scrap metal and unmelted scrap 48 . Two oxy/fuel burners 42 a and 42 b extend into the furnace 40 for igniting the tires and providing combustion oxygen. As the scrap tires burn, energy is added to the mass of scrap metal 48 and the scrap metal in the bundles and the remaining unmelted scrap metal is melted at a faster and more efficient rate than that ordinarily obtained. Molten slag floats to the top of the molten metal and the molten scrap metal is then poured out of the furnace 40 through pouring spout 44 . This embodiment presents significant advantages over the prior art and even is superior to merely combining the scrap rubber in the metal. With the scrap metal and scrap rubber being combined to form a scrap metal and rubber bundle, i.e., the scrap rubber intermixed with the scrap metal, the metal acts as a flame-spread reducer and also as a heat sink, thereby preventing rapid and uncontrolled burning of the scrap rubber. Further, the bundles may be picked up by a scrap magnet much as is done with the standard scrap metal bundles found in the industry today. The scrap metal/scrap rubber bundle thus provides a controlled rate of burning while also permitting relatively easy handling of the scrap rubber and scrap metal.
An additional important feature of the present invention is that the pollution emitted from the steel plant is greatly reduced when scrap rubber tires are added to the melting steel. When tires are added to the scrap metal the carbon monoxide emissions that normally occur from the arc furnace are greatly reduced. The tires act as a catalyst for carbon monoxide to carbon dioxide conversion. This also results in a much greater release of usable energy inside the furnace converting the energy therein where it has the most benefit for the melting of the steel. When conventional coal or coke is used, a lot of the available chemical energy is lost because the carbon in the fuel does not completely convert to carbon dioxide during the burning process. Numerous studies have been done looking into ways to increase the conversion rate and thus increase the efficiency of the melting process, including such methods as additional oxygen injection and other such techniques. The scrap rubber tires used in the method of the present invention provide at least a partial solution to this problem even if used only as a supplement to the coal or coke just for this purpose. More than half of the available energy is lost if the carbon is not allowed to react all the way to CO 2 . Often the carbon monoxide converts in the duct system outside of the furnace resulting in wasted energy, duct damage or even explosion, as it is a combustible gas. It has been found that the addition of the scrap tires as taught in the present invention will at least provide a partial solution to these problems. The inclusion of scrap tires in the melting process also has been shown to reduce NOx and SO 2 emissions when properly combusted in the EAF. This is another very important environmental consideration in steel mill operations and environmental operating permit compliance.
The use of TDF in the EAF also reduces the air pollution from the EAF process. TDF contains less carbon and therefore produces less carbon dioxide than coal or coke whether it is burned at the EAF or back at the electric utility. TDF contains twice as much hydrogen and burns hotter, i.e., it contains more fuel value. Additionally the hydrogen acts as a catalyst and reduces CO emissions, a very important and environmentally significant goal in the steel industry. The shredded tires can also be mixed with coal or coke and used to reduce CO emissions with a result being a greatly increased energy release from CO to CO 2 conversion.
An apparatus for practicing another preferred embodiment of the invention is schematically illustrated in FIG. 2 . Apparatuses similar to that shown in FIG. 1 have been given the same reference numerals. In FIG. 2 , a container 20 is mounted at a fixed location by conventional mounting means (not shown) so that it is close to the electric arc furnace 2 and has a removable control damper/cover 22 which is used to adjust the amount of combustible air available to the tires 100 which are to be burned within the container 20 thus regulating the rate of heat in the process. At least one oxy/gas burner 18 is connected to the container 20 to ignite the tires 100 within the container 20 , the oxy/gas burner 18 operating in a manner similar to that described previously in connection with the first embodiment. A pipe 30 extends between and is in fluid communication with the container 20 and the electric arc furnace 2 . A fume collecting system duct 24 is in fluid communication with the interior of the electric arc furnace 2 so that the heat generated by the burning of the tires 100 is drawn into the electric arc furnace 2 , the heat passing through the fume collecting system duct 24 . A molten metal conduit 4 is in fluid communication with the electric arc furnace 2 for releasing the molten metal from the electric arc furnace 2 . As the fume collecting system duct 24 draws the superheated air from the container 20 into the electric arc furnace 2 around the metal being melted in the electric arc furnace 2 , the heat generated by the burning tires adds to the heat generated by the oxy/gas burners in the electric arc furnace 2 thus decreasing the time and energy required to melt the steel and thus lowering the cost of steel production.
In practice, a quantity of whole, cut or shredded and de-wired rubber tires (not shown) is deposited into the container 20 and the oxy/gas burners 18 are used to ignite the whole, cut or shredded and de-wired rubber tires 100 to form combustible liquids and gases. The combustible liquids and gases flow through the pipe 30 thus adding their energy produced by combustion to the steel being melted in the electric arc furnace 2 .
Still another embodiment of the present invention would include a somewhat modified container 20 as described in connection with FIG. 2 . One of the problems with using tire derived fuel is the steel belts and beads that they contain. The steel generally does not belong in a combustion chamber as typically found in a coal or gas fired boiler or similar fuel burning system.
The tire-burning container 20 is a type of burner with tires as the fuel and with a supply of air or oxygen like most any conventional burner, similar to what was described previously. In this embodiment, however, the container 20 would include at the bottom of the container a cleanout opening for the metal residue. The tires in the container would be ignited so that they would decompose into combustible vapors and gasses. Just enough oxygen would be supplied to maintain this state, thus causing the tires to melt with the metal within the tires beginning to separate therefrom. The combustibles would then flow to an area where they would be mixed with additional oxygen and blown or drawn into the area where the heat was needed, such as a boiler or similar furnace firebox. The metal would separate and settle to the bottom of the container, as the melting point of the metal is higher than the melting point of the rubber. Not enough heat would be generated to melt the steel, just enough to separate the rubber materials from the steel. In this manner, the tires are broken down into combustible fluids that can be moved into an area where they can be burned as fuel while leaving the metal behind for disposal.
In a more complex device for a much larger application, the burner combustion would take place in a sloped rotary kiln, with the combustible products as vapors or gases leaving the upper opening and the metal waste discharging from the lower opening. The metal would be then be recyclable as steel scrap.
In either case the metal scrap would be condensed and much more easily handled then the wire that is currently generated when processing scrap tires. The cost would be much lower also when compared to conventional scrap tire processing with de-wiring and separation of the rubber from the metal. The inherent problems in the use of tires as fuel and the separation of the metal from the rubber are thus solved and the rubber can be burned for additional fuel while also allowing the scrap metal from the tires to be reused in a desired format.
It is contemplated that the inventive concepts herein described may be variously otherwise embodied and it is intended that the appended claims be construed to include alternative embodiments of the invention except insofar as limited by the prior art. For example, various types of furnaces may be used with the present invention, and the scrap tires may be of different types. Furthermore, different types of metals may be melted in the furnace besides the scrap metal, including such metals as iron pellets, direct reduced iron (“DRI”), pig iron and iron carbide, which are often scrap substitutes.
There has therefore been shown and described a process for melting scrap metal which accomplishes the stated objectives. | 4y
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TECHNICAL FIELD
This invention concerns a punch, more especially a manually operable punch of the type commonly used in offices, schools and similar establishments to form appropriately spaced holes in marginal edge regions of one or more sheets of paper to enable such sheets to be inserted into a loose-leaf binder.
BACKGROUND ART
Known punches of this type generally comprise a stationary base plate from which two upstanding side supports project. The side supports are sometimes integrally formed with the base plate, but are more often in the form of separate mirror image brackets welded to the base plate. Respective cylindrical cutting tools with downwardly directed cutting edges are mounted in the side supports and are axially movable against spring force upon depression of a handle or press bar which is pivotally connected between the side supports. When the press bar is actuated the tools are simultaneously pushed downwards so that their cutting edges co-operate with respective apertures in the base plate to cut holes in any sheets of paper inserted into a throat area between the side supports and the base plate.
Although two cutting tools are most common in punches of this type, any desired number may be provided. Moreover, three-or four-tool punches are particularly common in countries such as France, Sweden and U.S.A. to cut holes to correspond with standard binders used in those countries.
In addition to the variation in the number of cutting tools, the spacing between the respective cutting tools may vary to match the spacing of fastening means in different types of loose-leaf binders. In all, about nine different sizes of punch are currently on the market to cater for the varying requirements.
At present, the main structural components for punches of the type just described, namely the base plate, the side support brackets and the press bar, are individually cast or otherwise fabricated from mild steel. In addition, a tray moulded from plastics material is usually fitted to the underside of the base plate to retain the waste cuttings. Although the aforesaid mild steel construction gives the punch the necessary strength for cutting through several mm of paper, the cost of tooling up for fabricating components for one size of punch (i.e. one particular cutting tool spacing) amounts to many thousands of pounds. The cost of obtaining a mould for the tray is also very expensive. Accordingly, many manufacturers do not produce less popular punch sizes because it is not economically feasible to do so.
It is an object of the present invention to propose a novel design of punch which will allow manufacture by less expensive methods and with materials of less inherent strength than hitherto.
BRIEF SUMMARY OF THE INVENTION
With this object in view the present invention provides a punch comprising a support portion disposed above a base portion with respective parts of the support portion and the base portion juxtaposed to form a throat region and also constituting upper and lower cutting tool guide means, and a pivotal press bar whereby one or more spring-loaded cutting tools are pushed through openings in the aforesaid guide means, characterised in that the support portion and the base portion are formed as a single extruded profile, or as respective extruded profiles.
Respective end plates are preferably fitted onto opposing ends of the extruded profile or profiles so that the thickness of the extruded material (and hence the cost thereof) can be reduced while the overall strength and rigidity of the device is maintained.
Preferably, the press bar is formed as a separate extruded profile pivotally mounted between the respective end plates.
The extruded profile or profiles making up the main body of the punch (i.e. the base portion and the support portion) and the other extruded profile which constitutes the press bar are preferably formed of aluminium, although other extrudable materials are possible. Although aluminium is currently a more expensive material than mild steel, the cost of providing extrusion dies is so much less than the cost of tooling up for production of steel components that the overall cost of production of the proposed punch is less than that of conventionally constructed punches. What is even more significant is that punches of different sizes can readily be produced simply by using the same end plates and different lengths of the same extruded profiles, and by forming holes therethrough for guidance and support of the cutting tools at different positions, whereas previously a completely new set of production tools had to be made for each size of punch (i.e. each variation in the size of the separate components, or the number or spacing of the cutting tools).
Although aluminium extrusions are inherently less strong than the previously used mild steel fabrications the use of end plates to support the profile or profiles making up the main body of the punch imparts sufficient rigidity to the device as a whole that relative thin aluminium can be used. These end plates advantageously have lateral flanges or ribs in contact with or engaging at least part of the edge margins of the said profile or profiles.
In the case where the base portion and the support portion are formed of separate extrusions, the latter in particular may be formed of plastics. This will reduce the cost of materials, yet in view of the end plate support will not be detrimental to the overall strength and rigidity of the device.
The end plates are preferably moulded from plastics, e.g. high stress glass fiber reinforced nylon. The plastics is conveniently coloured to avoid the need for any additional finish and further reduce production costs.
The punch preferably also includes a tray which is removably attached to the underside of the base portion to retain waste cuttings for periodic disposal. This tray is advantageously in the form of a plastics extrusion with respective locator ribs for reception of downwardly projecting legs of the base portion only at two opposing sides (usually its front and rear edges. This sort of extruded tray is considerably less expensive to produce than the previously known moulded plastics tray with an all-round rim and, of course, the length of the proposed tray can readily be varied to match the length of the extruded profiles used for different sizes of punch.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described further, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is an inner side view of a left side end plate of a preferred practical embodiment of the punch of the invention;
FIG. 2 is an end view of a first extruded profile constituting the main body of the same embodiment of the punch of the invention;
FIG. 3 is an end view of a tray to be fitted beneath the profile shown in FIG. 2;
FIG. 4 is an inner side view of a right angle side end plate of the same embodiment of the punch of the invention;
FIG. 5 is an end view of a second extruded profile which constitutes the press bar of the same embodiment of the punch of the invention;
FIG. 6 is a cross-section of the said preferred embodiment of the punch of the invention showing how the components illustrated separately in FIGS. 1, 2, 3 and 5 are fitted together;
FIG. 7 is a plan view of the punch shown in FIG. 6;
FIG. 8 is an end view of an alternative construction of press bar;
FIG. 9 is an enlarged view, similar to the lower right hand portion of FIG. 6, illustrating the position of a paper gauge in a modified embodiment of the punch of the invention;
FIG. 10 is a reduced scale side view of the paper gauge indicated in FIGS. 6 and 7;
FIG. 11 is a top side view of the same paper gauge; and
FIG. 12 is a schematic end view of two interengaged profiles constituting the main body of an alternative embodiment of the punch of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As illustrated in FIGS. 1 to 7, a preferred practical embodiment of the punch of the invention comprises a main body profile 10 (FIG. 2), respective end plates 11 and 12 (FIGS. 1 and 4), a tray 13 (FIG. 3), a press bar 14 (FIG. 5) and two cylindrical cutting tools 15 assembled together as indicated in FIGS. 6 and 7.
With reference to FIG. 2, the main body profile consists of a single aluminium extrusion of any desired length. It can be approximately divided into a support portion 19 disposed above a base portion 20. The support portion 19 may in turn be subdivided into an upper cutting tool guide 21, and an upstanding front portion 22 having a rearwardly directed auxiliary cutting tool guide platform 23 extending therefrom. The base portion 20 is generally rectangular in plan and is provided with front, intermediate and rear downwardly directed legs, 24, 25, 26 respectively, to support the punch upon a flat surface, such as a desk top. The intermediate leg 25 is only a short spacing behind the front leg 24. It provides additional stiffening and also delimits a frontal space beneath the base portion 20 in which a paper gauge 50 may be located, as will be described later.
The base portion 20 has a substantially horizontal rear part which connects to a substantially horizontal front part by way of a downward step or joggle 27 approximately in the middle of the portion 20. The upper cutting tool guide 21 extends above the front part of the base portion 20 (which provides a power cutting tool guide) and inclines upwardly from the top of the step 27 until it merges into the upwardly projecting front portion 22 at a point lying above the region between the intermediate leg 25 and the front leg 24. The gap remaining between the front part of the base portion 20 (the lower cutting tool guide) and the upper cutting tool guide 21 forms the throat of the punch which receives edge margins of sheets of paper in which holes are to be cut, the edges of the paper being pushed into abutment against the step 27.
At its upper margin, the front portion 22 inclines rearwardly and on its inner surface, above the auxiliary guide platform 23, it is provided with a groove 37 of part-spherical cross-section for reception of a presser bar shaft, as mentioned hereinafter.
The tray 13 consists of a plastics extrusion which is cut so as to be slightly longer than the profile 10 and is fitted to the underside of the profile 10. The tray 13 has respective inwardly inclined locator ribs 28, 29 at front and rear for engagement over the front and rear legs 24, 26 of the profile 10. It also has an inclined deflector region 30 which is located beneath the throat of the punch and deflects waste cuttings falling through the base portion 20 of the profile 10 towards the rear of the tray 13 so that the tray 13 does not become clogged immediately below the throat.
The left and right side end plates 11, 12, each consisting of a tough coloured plastics moulding, are shown in FIGS. 1 and 4 respectively. Each plate 11, 12 is roughly triangular in shape with an apex towards the front of the punch. They are shaped to cover the respective ends of the profile 10 and are provided with an plurality of flanges or ribs 31 which project inwardly of the assembled punch and fit closely around most parts of the profile edge margins, as indicated in FIG. 4, to give support to same. In this way, the end plates 11, 12, when fitted onto the ends of the main body profile 10 impart strength and rigidity to the entire device.
The left and right side end plates 11, 12 are not exactly symmetrical mirror images as the left side end plate 11 is provided with a straight lower edge which abuts the end of the tray 13 which is fitted to the underside of the profile 10, whilst the right side end plate 12 has a lower edge which is shaped to finish just above its respective end of the tray 13. The tray 13 can thus be readily removed from the underside of the profile 10 to empty out accumulated waste cuttings by sliding it towards the right side end of the punch.
The end plates 11, 12 are also provided on their inwardly directed faces with upper and lower stops 32, 33 which serve to limit the pivotal movement of the press bar 14 (see FIG. 6). The lower stop 32 is provided by the upper surface of a flange where it is diverted inwardly from the rearwardly sloping upper edge of each end plate 11, 12. The upper stop 33 is provided by the lower edge of a flange which partially surrounds a press bar pivot point 34 near the apex of each end plate 11, 12.
The end plates 11, 12 are also provided with three fixing holes 35 in line with respective fixing grooves 36 formed on the main body profile 10. Screws or other fastening means may be used to secure the plates 11, 12 to the profile 10 by insertion through the holes 35 and engagement in the corresponding grooves 36.
The press bar 14 (FIG. 5) consists of a further aluminium extrusion of slightly greater length than the main body profile 10. An integral pivot shaft 39 is formed along one edge of the press bar 14 and adjacent this is a small ridge 40 which serves to contact and transmit pressure to the top of the cutting tools 15 (see FIG. 6).
The pivot shaft 39 fits into the groove 37 behind the upright front portion 22 of the main profile 10, by being slidingly inserted from one end, and is then retained between the respective pivot points 34 provided on the edge plates 11, 12.
With reference to FIG. 6, two appropriately spaced circular openings 42 are provided in the auxiliary guide platform 23 and, in vertical alignment therewith similar openings 43 are provided in the upper cutting tool guide 21 and in the front part of the base portion 20, which effectively constitutes a lower cutting tool guide as well as a cutting surface. Respective cylindrical steel cutting tools 15 with downwardly directed cutting edges are mounted in the openings 42 by means of encircling helical springs 45 which act between the upper cutting tool guide 21 and a circlip 46 attached to each tool 15 which is urged into abutment against the auxiliary guide platform 23. A rounded plastics cap 47 is provided at the top of each cutting tool 15 as a reliable contact surface for the ridge 40 of the handle 14.
When the press bar 14 is depressed (as indicated by the arrow in FIG. 6) the cutting tools 15 are moved downwards against the action of the springs 45 so that the cutting edges pass through the openings 43 and pierce any paper located in the throat of the punch. As soon as the press bar 14 is released the springs 45 return the tools 15 and the presser bar 14 to their original (upper) position. The circles of paper cut out by the interaction of the cutting edges of the tools 15 and the openings in the base portion 20 are deflected rearwardly by the deflector region 30 of the tray 13, which is periodically removed and emptied, by being slid off at the right hand end of the punch.
The mechanical stresses arising upon use of the punch are primarily borne by the respective end plates 11, 12 as the groove 37 at the upper edge margin of the front portion 22 simply serves as a guide for the pivot shaft 39 of the press bar 14. Other stresses on the main extruded profile 10 are also, in part, transmitted to the end plates 11, 12 by virtue of the interengagement of the support flanges or ribs 31 with the opposite ends of the profile 10.
Optionally, a slidably extensible paper gauge 50, which serves for alignment of sheets of paper so that holes are formed in the correct position relative to one end thereof, may be provided in the frontal space 44 between the front leg 24 and the intermediate leg 25 of the base portion 20, as indicated in FIGS. 6, 7 and 9. Such a gauge 50 is illustrated in FIGS. 10 and 11. It is in the form of a thin plastics strip of T-shaped cross-section which can be pulled through apertures in the end plates 11, 12 by a user holding a terminal ridge 51, and can be temporarily retained at appropriate positions by engagement of one of a plurality of notches 52 formed in its vertical limb with the lower edge of one of the apertures. Appropriate ribs or flanges 38 are provided on the profile 10, in the area 44, to form a T-shaped slot for accommodating this gauge 50.
It should be appreciated that the invention is not limited to the exact details of the above-described embodiment and many variations are possible. In particular, if three or four cutting tools are required they can readily be mounted in similar manner to the two tools in the above-described embodiment and appropriate openings formed in the cutting tool guide, and the guide platform and the base portion. For different tool spacings, the openings are simply formed as required in the extruded profile 10 and of course the length of the profile 10 and of the tray 13 and the presser bar 14 can be chosen to accommodate wider spacings and/or more cutting tools for larger size punches.
A slightly modified presser bar is illustrated in FIG. 8. This has a decorative PVC (polyvinyl chloride) panel 53 fitted into an appropriately shaped recess 54 in its upper surface. Also, in place of a ridge 40, it has an arcuate portion 55 for contact with the tops of the cutting tools. This presser bar can, of course, be used in place of the bar 14 in the above-described embodiment.
In a more significantly different embodiment of the invention, the base portion 120 and the support portion 119 of the main body of the punch may be formed as separate extrusions, the former of aluminium and the later of plastics. These are advantageously shaped for mutual interengagement e.g. by dovetail portions 118 as indicated in FIG. 12. The strength and rigidity of the punch is still maintained by end plates which have appropriately spaced ribs 31 to accommodate the broader central region where the two extrusions are in engagement. Otherwise, the principles of construction would be exactly as in the above-described embodiment. Although an extra extrusion die would be required, the use of plastics for one of the extrusions would reduce the cost of materials. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the device structure for the interconnection of semiconductor devices on a substrate and more particularly to a multilayered sputtered interconnect metallurgy structure which structure includes a low percent copper content aluminum/copper conductor.
2. Description of Related Art
Thin narrow interconnections have been used for some years for device interconnection purposes in the semiconductor integrated circuit industry. It is predicted that performance of these devices in the future will be limited by the performance of the device interconnection at the submicron level. At the submicron level, various technical problems are known to occur. While aluminum has been the preferred interconnection metal, as device dimensions are scaled down and current density increases, pure aluminum has been known to be susceptible to the problems of electromigration and hillock growth. To overcome the problems experienced with pure aluminum, aluminum has been alloyed with copper to form aluminum-copper. However, high percentage aluminum-copper (>2%) is known to be difficult to dry etch and corrodes easily.
In an effort to improve on the use of aluminum-copper as the interconnection metallurgy, aluminum-copper has been taught to be layered with a refractory metal (i.e., U.S. Pat. No. 4,017,890). This patent teaches a method and resulting structure for forming narrow intermetallic stripes which carry high currents on bodies such as semiconductors, integrated circuits, etc., wherein the conductive stripe includes aluminum or aluminum-copper with at least one transition metal. While the aluminum-copper and transition metal structure has been known to improve the electromigration problems associated with aluminum-copper, the problems of etching and corrosion, as well as, the complete elimination of hillocks have not been solved.
As known in the art, hillocks are known to result from the large differences between the thermal expansion coefficients of the metal interconnect lines and the substrate. To eliminate and minimize hillock formation, it has been known in the art to use a multilayered structure instead of a single layer of the interconnect metallurgy. An effective reduction in hillock formation has been found to be achieved by using a multilayered structure of aluminum or aluminum intermetallic with a layer of refractory metal. Wherefore, a typical interconnect metallurgy structure would comprise a layered structure of aluminum silicon compound onto which there has been deposited, a layer of refractory metal, such as, titanium (see article "Homogeneous and Layered Films of Aluminum/Silicon with Titanium For Multilevel Interconnects", 1988 IEEE, V-MIC Conference, June 25-26, 1985).
There have also been refinements to this layered metal structure to provide a lower resistivity, hillock free, interconnect metallurgy. These refinements include the incorporation of a barrier metal of, for example, titanium tungsten or titanium nitride under the aluminum silicon to prevent contact spiking and prevent the formation of ternary compounds in the aluminum silicon alloy (see article "Multilayered Interconnections For VLSI" MRS Symposia Proceedings, Fall, 1987).
In addition, in this area, there have also been other proposed device interconnect structures to reduce resistivity and provide a more planar and defect free interconnect structure.
For example, IBM Technical Disclosure Bulletin, Vol. 21, No. 11, April, 1979, pp. 4527-4528, teaches the enhancement of the metallurgy for the interconnection due to sputtered deposition. Moreover, the feature of using a capping layer to improve performance has been proposed in IBM TDB Vol. 17, No. 1A, 1984 and TDB Vol. 21, No. 2, July 1978. However, no structure has been discovered which can satisfy all performance criteria providing a low resistance, hillock free, corrosion resistant, etchable, interconnection metallurgy structure.
It is, therefore, an object of the present invention to provide sputtered low weight percent copper (<2%) content aluminum/copper conductor for device interconnection on a substrate with superior electromigration characteristics.
It is a still further object of the present invention to develop a multilayered interconnect metallurgy structure that is hillock free, dry etchable and corrosion resistant.
It is another object of the present invention to provide a multilayered interconnect metallurgy structure which has a low resistivity.
SUMMARY OF THE INVENTION
A sputtered low-copper concentration multilayered, device interconnect metallurgy structure is disclosed herein. The interconnect metallization structure comprises a sputtered aluminum-copper (<2) weight percent copper conductor. In the preferred embodiment, the conductor layer is formed with a top and bottom layer of an intermetallic, said intermetallic also being sputtered and being of a thickness of approximately 700 Å. Onto said intermetallic layer is further deposited an etch stop, and non-corrosive, protective capping layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the preferred embodiment of an interconnect metallurgy according to the subject invention.
FIGS. 2 through 8 are cross-sectional views of the process for building the preferred interconnect metallurgy of the subject invention in a step-by-step fashion.
FIG. 9 is a graph of the lifetime (hours) versus weight percent copper for interconnect metalluries of the subject invention as compared to prior art interconnect metallizations.
FIG. 10 is a graph of the resistivity versus weight percent copper for various alternative embodiment metallurgies of the subject invention before and after anneal.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a cross-sectional view of the preferred embodiment of an interconnect metallurgy structure according to the subject invention. FIG. 1 represents the interconnect structure after being processed through final annealing.
Referring to FIG. 1, the interconnect metallurgy is seen to comprise a four-layer structure over an interplanar stud connection 10 surrounded by an insulator 8 to make connection to a device substrate 6. The four-layer structure consists of a bottom-sputtered layer 13 of an intermetallic formed by the reaction between the conductor layer 14 and pre-annealed surface layer 12 (see FIGS. 2-7). The layer 13 is typically 700 Å thick and in a preferred embodiment would comprise TiAl 3 . Onto said sputtered intermetallic layer 13 is a sputter-deposited, low percent (<2) weight percent copper, aluminum-copper, conductor layer 14. After annealing, the layer 14 is typically 8,500 Å thick and consists of a composition of 99.5% aluminum and 0.5% copper (aluminum-0.5% copper hereafter). On layer 14 is a second intermetallic layer 15 of the same thickness and composition as the layer 13. A layer 18 of aluminum-0.5% copper or pure aluminum of approximately 100 Å to 500 Å thick is then sputter deposited to cap the structure. While this completes the structure for a single interconnect layer according to the subject invention, it should be recognized by those skilled in the art that said layers can then be repeated in a multiple level sequence to complete the interconnect circuit for the devices.
Referring now to FIG. 2, FIG. 2 shows a planar insulator 8 and contact stud 10 with a Group IVA metal layer 12 sputter deposited thereon. The layer 12 is deposited by the following process. After formation of the device contact metallization 10, the semiconductor wafer would be loaded into a sputtering tool which has been pumped to a low pressure. An in-situ sputter clean is then performed to remove any oxide from the contact metal 10 formation on the wafer at this time. This in-situ sputter clean typically is a mild sputter clean, run, for example, at about five minutes at low power (approximately 1,000 watt) in a high-pressure argon ambient.
Following the sputter cleaning, the first level of metallization 12 is then deposited. This first level metallization 12 is comprised of a Group IVA metal, preferably titanium, deposited on the device contact metallization 10 of the wafer in a blanket formation. This layer 12 is deposited at low power in a high pressure, high purity, argon plasma from an ultra-pure titanium target at a rate of about 60 Å per minute. Preferably, the titanium is deposited to a thickness of approximately 250 Å.
Referring now to FIG. 3, following the deposition of the layer 12, the interconnect metallization layer 14 is next blanket deposited. The interconnect metallization 14 is preferably aluminum-0.5% copper (approximately 9,500 Å thick). The aluminum-copper is deposited at high power using a direct current magnetron in a high purity argon plasma from an ultra-pure pre-alloyed target typically aluminum-0.5 weight percent copper with a deposition rate of about 1,500 Å per minute.
Onto said aluminum-copper interconnect metallization 14 is then deposited 250 Å of a Group IVA metal similar to the previously deposited metal layer 12 discussed above. Deposition, composition and thickness of said layer 16 is identical to the previously deposited layer 12 (FIG. 4).
From FIG. 5, onto said metal layer 16 is then blanket deposited a suitable capping layer 18 to complete the interconnect metallurgy at this level. The capping layer 18 is preferably comprised of aluminum-0.05% copper deposited in the same manner as the conductor aluminum-0.05% copper layer 14 as discussed above. The purpose of this layer is to: 1) prevent over-etch of metal layer 16; 2) limit the amount of light reflection during the subsequent photoresist steps, and 3) to act as a protective layer against corrosion during subsequent processing. Therefore, any layer which would similarly satisfy the requirements of reducing the amount of light reflection and provide protective anodic capping during subsequent processing would be usable for this layer (e.g. pure aluminum).
Referring now to FIG. 6, on top of metallization 18, a multilayered photoresist (20, 22 and 24) is then applied to pattern this blanket interconnect metallization. Any number of different photoresist techniques can be used. In particular, multilayered photoresists are well suited for this purpose, as well as, single-layered resists.
With a multilayered resist as shown in FIG. 6, a first resist 20 is applied to a thickness of approximately 1.8 micrometers. In the preferred embodiment this resist is a diazo-quinone novolak photoresist. The resist 20 is baked in an oven in a nitrogen ambient at about 200° C. for 30 minutes. This resist 20 serves as a sacrificial layer during subsequent metal reactive ion etching (RIE).
Onto said resist 20 is then deposited 200 Å of a silylating agent 22, such as, HMDS (hexamethyldisilizane). The HMDS 22 serves as a barrier to the oxygen reactive ion etching which is used to pattern the imaging layer resist 24.
Onto said HMDS layer 22 is next deposited an imaging layer resist 24 to a thickness of about 0.9-1.2 micrometers. Similar to resist 20, imaging resist 24 is a diazo-quinone novolak positive photoresist. The HMDS 22 and imaging resist layer 24 are then baked on a hot plate for 25 minutes at 85° C.
The imaging layer resist 24 is then exposed for the specific time required when used in conjunction with a specific exposure tool and associated mask. The exposed image is developed using conventional developing for the required time depending on the exposure. The wafer is then rinsed and dried and the patterned top imaging layer is UV hardened by exposing it to ultraviolet light for a specific period of time, typically, 5 to 10 minutes.
Following the patterning of the top imaging resist 24, the HMDS 22 and resist layer 20 are ready to be removed to expose the metal. The HMDS 22 and the resist 20 are removed by reactive ion etching. This is accomplished by loading the wafer into a plasma tool and exposing the wafer to a plasma reactive to the HMDS layer 22 (e.g. CF 4 ) and then to a different plasma (e.g. O 2 ) reactive to resist 20. The polymer residues of the remains of the HMDS layer 22 and the resist 20 are then removed by dipping in a solution of a conventional cleaning etch solution. This reactive ion etching of the HMDS layer 22 and the resist 20, has put a lithographic mask into place for the subsequent reactive ion etching of the underlying blanket metal layers.
The metallurgy can now be reactively ion etched in a multi-step sequence. The first step is to break through any oxides which may exist on the top surface of the metallization. Next, most of the metal is removed by reactive ion etching. An over etch is, then, performed to insure that all of the metal in the previous step has been etched away. Finally, a passivation step is performed to prevent any metal corrosion.
The reactive ion etch is typically performed in a single wafer tool under a low pressure. Typical plasma composition, pressure, power and time combinations, for performing the above etches in a step-by-step process can be seen from the following Table I. These compositions, pressures, powers and times should be recognized by those skilled in the art as being designed for a specific tool under specific conditions. Any comparable times, compositions, pressure, etc., could be similarly fabricated to insure the etch of the blanket metallization.
TABLE I______________________________________Gas Flow (cc/min) Step 1 Step 2 Step 3 Exit______________________________________BCl.sub.3 20 12 12 --Cl.sub.2 11 11 8 --CHCl.sub.3 5 16 16 --N.sub.2 50 50 50 --CF.sub.4 -- -- -- 180O.sub.2 -- -- -- 20Pressure 375 375 375 0.5 Torr(milli-Torr)Power (Watts) 485 350 350 130Typical Times 15 2-3 40 20 sec min sec sec______________________________________
With the completion of the reactive ion etch, the wafer can then be rinsed and dried.
Referring now to FIG. 7, it can be seen that the reactive ion etch of the metal removes any of the remaining imaging layer resist 24 and most of the HMDS layer 22 leaving on the surface of the metal the resist 20. This resist 20 can be removed by placing the wafer in an oxygen plasma for approximately 45 minutes. The wafer is then placed in a developer at room temperature for a short period of time to remove any oxides that may have formed in the previous step. The wafer is again rinsed and dried.
With removal of this final layer of the resist 20, the metallization stack can now be annealed by placing the wafer in an oven at 400° C. in forming gas for 1 hour in order to form TiAl 3 intermetallic layers 13 and 15 (as shown in FIGS. 1 and 8) on the top and the bottom of the aluminum-copper layer 14 and to allow grain growth to occur in the aluminum-copper layer 14.
From FIG. 8, it can be seen that once the metallization stack has been annealed (to the structure of FIG. 1) a suitable insulator 26 (e.g., planar quartz or plasma-enhanced CVD oxide or an organic insulator such as polyimide) can be blanket deposited over the multilayered interconnect structure. This insulator 26 can then be planarized and/or patterned for stud connection to the repeating interconnect layers deposited onto the base interconnect layer.
The superior performance of the interconnect metallurgy of the subject invention over that which is known in the prior art can be seen in the following figures. FIG. 9 is a lifetime (hours) versus weight percent copper graph for the electromigration characteristics of both the above-described sputtered four-layered structure and an alternative sputtered three-layer structure (Al/Cu/refractory metal/Al-Cu), as compared to an evaporated three-layer structure patterned by lift-off and an evaporated four-layer structure, patterned by RIE. From FIG. 9 it can be seen that for all weight percent copper compositions, the sputtered interconnect metallurgies are vastly superior to the evaporated metallurgies.
FIG. 10 is a graph of the resistivity versus weight percent copper for various alternative embodiment metallurgies of the subject invention. The metallurgies have been subjected to a 400° C. forming gas anneal wherein the plots have been taken both before and after said anneal. From the plots it can clearly be seen that the resistivity of the 0.5 weight percent copper structures are lower than that of the higher weight percent copper films. Additionally, it can also be seen that the annealed films of the four-layer structure have a lower resistivity than the annealed films of the three-layer structure.
The following Table II is a further comparison of the electromigration characteristics of sputtered Al-0.5% Cu metallurgy after annealing with intermetallic formation as compared to various other interconnect metallugies.
TABLE II______________________________________ RESISTIVITY (μΩ-cm) T(50%) 1 hr, 400 C. 250 C., 2.5E + 06A/cm.sup.2ALLOY Forming Gas (Hours)______________________________________Al-0.5% Cu (Ref.#1) 3.5 9000Al-0.5% Cu (Ref.#2) 3.4 12000Evap (Ref.#3) 3.7 400-500Evap (Ref.#4) 3.8 400-500Cr/Al-4% Cu 3.0 400Al 2.8 15Al-0.5% Cu 2.9 50Al-1.2% Si-0.15% Ti 3.1 23Al-1.2% Si (Ref.#5) 2.9 156*Al-1% Ti 6.6 2Al--Si/Ti (Ref.#6) 3.1 300*______________________________________ *150 C., 1E + 06 A/cm.sup.2, unpassivated 1. Sputtered 4250Å Al0.5% Cu/1500Å TiAl.sub.3 /4250Å Al0.5% C and annealed in forming gas at 400° C. 2. Sputtered 700Å TiAl.sub.3 /8500Å Al0.5% Cu/700Å TiAl.sub.3 /250Å Al0.5% Cu and annealed in forming gas at 400° C. 3. Evaporated 4250Å Al0.5% Cu/1500Å TiAl.sub.3 /4250Å Al0.5% Cu and annealed in forming gas at 400° C. 4. Evaporate 700Å TiAl.sub.3 /8500Å Al0.5% Cu/700Å TiAl.sub.3 /250 Al0.5% Cu and annealed in forming gas at 400° C. 5. F. Fisher, Siemens ForschU. EntwicklDec. 13, 21 (1984). 6. D. S. Gardner, T. L. Michalka, P. A. Flinn, T. W. Barbee Jr., K. C. Saraswat & J. D. Meindl, Proc. 2nd IEEE VMIC, pp. 102-113 (1985).
From the table it can be seen that the sputtered 0.5% copper metallurgy provides the longest electro-migration capability with the lowest resistivity.
In general, while the corrosion resistance of bulk aluminum is greatly decreased by the addition of copper, it is known and recognized in the art (see, for example, J. Zahavi, M. Rotel, H. C. W. Huang, P. A. Totta, "Corrosion behavior of Al-Cu Alloy Thin Films in Microelectronics." Electrical Society Extended Abstracts, Vol. 84-2, Fall, 1984 that the corrosion resistance of reactive ion etched low copper containing films of aluminum (e.g., less than 1% copper) are at least as good as bulk aluminum. This is in contradiction to that skill in the art which recognizes that the corrosion resistance of higher percentage (above 1%) copper-aluminum films significantly degrades below that of pure aluminum. While detailed understanding of the mechanism of the performance of the subject interconnect metallurgy is not known, several principles have been extended by the inventors to explain the superior electromigration and resistivity results as seen above.
The solubility of copper and aluminum is known to decrease from 5.65 wt. % at 548° C. to 0.25 wt. % at room temperature. Therefore, the 0.5% copper film composition of the subject invention has enough copper without theta phase formation to improve both the mechanical properties and reliability, (e.g., electro-migration properties) of the alloy over pure aluminum. Moreover, it is recognized that there is enhanced copper uniformity in the subject films due to the fact that said films were sputtered versus the non-uniformity in copper distribution as can be seen in the evaporated aluminum-copper films. In addition, it is also recognized that evaporation results in the uneven distribution of theta particles in the evaporated films which uneven distribution is known to contribute to the poor mechanical corrosion and electrical properties of the prior art films. The superior mechanical and electrical properties of the subject metallurgy is therefore directly attributed to the enhanced copper uniformity in these films as result of the deposition by sputtering. Therefore, an improved sputtered copper interconnect metallurgy has been developed that has enhanced reliability, lower resistivity, is dry etchable, and has a superior corrosion resistance than that metallurgy as presently used in the prior art. The preferred sputtered (4-layer) metallurgy exhibits lower resistivity and superior electromigration over a wider range of copper compositions than previous prior art structures.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that 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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TECHNICAL FIELD
[0001] The illustrative embodiments generally relate to a method and apparatus for providing parking instructions to reduce environmental vehicle effects.
BACKGROUND
[0002] The lithium ion batteries for a midrange Battery Electric Vehicle (BEV) can cost between $12,000 and $15,000, making it is the most expensive component of the vehicle (constituting some 38% of the total vehicle cost to the consumer). Accordingly, a major customer concern is the cost of a battery failure, so competitive vehicles must carry a long warrantee on the battery (often, for example, 8 years or 100,000 miles).
[0003] Presently BEV battery failures are rare, but BEV vehicles are too expensive to compete with conventional vehicles and they are produced in very low numbers. Cost reduction and increasing assembly volumes can only be maximized by designing batteries that meet the minimum ruggedness requirements consistent with lifetime cost of the vehicle. It is possible to reduce the ruggedness requirements and consequently the manufacturing cost of the battery through several methods often only if significant computational and data acquisition and storage capacity is available.
[0004] U.S. Patent Application 2009/0157232 generally relates to a method for preserving battery operation and life during vehicle post idle shutdown, such vehicle having a delayed accessory power mode operative when an ignition state of the vehicle is in a non-engine running condition while an ignition switch of the vehicle is in the ON position to supply accessories in the vehicle the battery. The method includes: detecting whether the vehicle has been in an post idle shutdown condition and brake pedal not pressed and ignition state unchanged; and placing the vehicle in the delayed accessory power mode after detecting that the vehicle has been in an post idle shutdown condition and while the ignition switch is in the ON position.
SUMMARY
[0005] In a first illustrative embodiment, a system includes a processor configured to receive parking space environmental characteristics, from a vehicle parked in a parking space. The processor is also configured to download weather data for an area in which the parking space is located, covering a time duration for which the vehicle was parked. The processor is further configured to correlate the weather data to the received environmental characteristics to build a parking space environment profile for the duration of time and update a parking space model based on the environment profile.
[0006] In a second illustrative embodiment, a system includes a processor configured to determine that a vehicle is proximate to a parking location. The processor is also configured to retrieve an environmental model for the parking location. The processor is further configured to retrieve weather data for the parking location. Also, the processor is configured to build a forecast model for the parking location covering an estimated parking duration. The processor is additionally configured to determine a first parking space having better battery life preservation likelihood than another parking space, within the parking location, based on the forecast model and recommend the first parking space.
[0007] In a third illustrative embodiment, a system includes a processor configured to receive an estimated parking duration for a parked vehicle. The processor is also configured to receive an forecast model for a parking space in which the vehicle is parked. Further, the processor is configured to determine a surplus amount of battery energy. The processor is also configured to determine a cooling strategy for a vehicle battery, based on the surplus energy and the forecast model and implement the cooling strategy at least while the vehicle remains parked.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows an illustrative vehicle computing system;
[0009] FIG. 2 shows an illustrative process for data gathering;
[0010] FIG. 3 shows an illustrative process for further data gathering;
[0011] FIG. 4 shows an illustrative process for parking location recommendation;
[0012] FIG. 5 shows an illustrative charging process, incorporating battery life preservation; and
[0013] FIG. 6 shows a further illustrative charging process, incorporating battery life preservation.
DETAILED DESCRIPTION
[0014] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0015] FIG. 1 illustrates an example block topology for a vehicle based computing system 1 (VCS) for a vehicle 31 . An example of such a vehicle-based computing system 1 is the SYNC system manufactured by THE FORD MOTOR COMPANY. A vehicle enabled with a vehicle-based computing system may contain a visual front end interface 4 located in the vehicle. The user may also be able to interact with the interface if it is provided, for example, with a touch sensitive screen. In another illustrative embodiment, the interaction occurs through, button presses, audible speech and speech synthesis.
[0016] In the illustrative embodiment 1 shown in FIG. 1 , a processor 3 controls at least some portion of the operation of the vehicle-based computing system. Provided within the vehicle, the processor allows onboard processing of commands and routines. Further, the processor is connected to both non-persistent 5 and persistent storage 7 . In this illustrative embodiment, the non-persistent storage is random access memory (RAM) and the persistent storage is a hard disk drive (HDD) or flash memory.
[0017] The processor is also provided with a number of different inputs allowing the user to interface with the processor. In this illustrative embodiment, a microphone 29 , an auxiliary input 25 (for input 33 ), a universal serial bus (USB) input 23 , a global positioning system (GPS) input 24 and a BLUETOOTH input 15 are all provided. An input selector 51 is also provided, to allow a user to swap between various inputs. Input to both the microphone and the auxiliary connector is converted from analog to digital by a converter 27 before being passed to the processor. Although not shown, numerous of the vehicle components and auxiliary components in communication with the VCS may use a vehicle network (such as, but not limited to, a controller area network (CAN) bus) to pass data to and from the VCS (or components thereof).
[0018] Outputs to the system can include, but are not limited to, a visual display 4 and a speaker 13 or stereo system output. The speaker is connected to an amplifier 11 and receives its signal from the processor 3 through a digital-to-analog converter 9 . Output can also be made to a remote BLUETOOTH device such as personal navigation device (PND) 54 or a USB device such as vehicle navigation device 60 along the bi-directional data streams shown at 19 and 21 respectively.
[0019] In one illustrative embodiment, the system 1 uses the BLUETOOTH transceiver 15 to communicate 17 with a user's nomadic device 53 (e.g., cell phone, smart phone, personal digital assistant (PDA), or any other device having wireless remote network connectivity). The nomadic device can then be used to communicate 59 with a network 61 outside the vehicle 31 through, for example, communication 55 with a cellular tower 57 . In some embodiments, tower 57 may be a WiFi access point.
[0020] Exemplary communication between the nomadic device and the BLUETOOTH transceiver is represented by signal 14 .
[0021] Pairing a nomadic device 53 and the BLUETOOTH transceiver 15 can be instructed through a button 52 or similar input. Accordingly, the central processing unit (CPU) is instructed that the onboard BLUETOOTH transceiver will be paired with a BLUETOOTH transceiver in a nomadic device.
[0022] Data may be communicated between CPU 3 and network 61 utilizing, for example, a data-plan, data over voice, or dual-tone multi-frequency (DTMF) tones associated with nomadic device 53 . Alternatively, it may be desirable to include an onboard modem 63 having antenna 18 in order to communicate 16 data between CPU 3 and network 61 over the voice band. The nomadic device 53 can then be used to communicate 59 with a network 61 outside the vehicle 31 through, for example, communication 55 with a cellular tower 57 . In some embodiments, the modem 63 may establish communication 20 with the tower 57 for communicating with network 61 . As a non-limiting example, modem 63 may be a USB cellular modem and communication 20 may be cellular communication.
[0023] In one illustrative embodiment, the processor is provided with an operating system including an API to communicate with modem application software. The modem application software may access an embedded module or firmware on the BLUETOOTH transceiver to complete wireless communication with a remote BLUETOOTH transceiver (such as that found in a nomadic device). Bluetooth is a subset of the IEEE 802 PAN (personal area network) protocols. IEEE 802 LAN (local area network) protocols include WiFi and have considerable cross-functionality with IEEE 802 PAN. Both are suitable for wireless communication within a vehicle. Another communication means that can be used in this realm is free-space optical communication (such as infrared data association (IrDA)) and non-standardized consumer infrared (IR) protocols.
[0024] In another embodiment, nomadic device 53 includes a modem for voice band or broadband data communication. In the data-over-voice embodiment, a technique known as frequency division multiplexing may be implemented when the owner of the nomadic device can talk over the device while data is being transferred. At other times, when the owner is not using the device, the data transfer can use the whole bandwidth (300 Hz to 3.4 kHz in one example). While frequency division multiplexing may be common for analog cellular communication between the vehicle and the internet, and is still used, it has been largely replaced by hybrids of with Code Domian Multiple Access (CDMA), Time Domain Multiple Access (TDMA), Space-Domian Multiple Access (SDMA) for digital cellular communication. These are all ITU IMT-2000 (3G) compliant standards and offer data rates up to 2 mbs for stationary or walking users and 385 kbs for users in a moving vehicle. 3G standards are now being replaced by IMT-Advanced (4G) which offers 100 mbs for users in a vehicle and 1 gbs for stationary users. If the user has a data-plan associated with the nomadic device, it is possible that the data-plan allows for broad-band transmission and the system could use a much wider bandwidth (speeding up data transfer). In still another embodiment, nomadic device 53 is replaced with a cellular communication device (not shown) that is installed to vehicle 31 . In yet another embodiment, the ND 53 may be a wireless local area network (LAN) device capable of communication over, for example (and without limitation), an 802.11g network (i.e., WiFi) or a WiMax network.
[0025] In one embodiment, incoming data can be passed through the nomadic device via a data-over-voice or data-plan, through the onboard BLUETOOTH transceiver and into the vehicle's internal processor 3 . In the case of certain temporary data, for example, the data can be stored on the HDD or other storage media 7 until such time as the data is no longer needed.
[0026] Additional sources that may interface with the vehicle include a personal navigation device 54 , having, for example, a USB connection 56 and/or an antenna 58 , a vehicle navigation device 60 having a USB 62 or other connection, an onboard GPS device 24 , or remote navigation system (not shown) having connectivity to network 61 . USB is one of a class of serial networking protocols. IEEE 1394 (firewire), EIA (Electronics Industry Association) serial protocols, IEEE 1284 (Centronics Port), S/PDIF (Sony/Philips Digital Interconnect Format) and USB-IF (USB Implementers Forum) form the backbone of the device-device serial standards. Most of the protocols can be implemented for either electrical or optical communication.
[0027] Further, the CPU could be in communication with a variety of other auxiliary devices 65 . These devices can be connected through a wireless 67 or wired 69 connection. Auxiliary device 65 may include, but are not limited to, personal media players, wireless health devices, portable computers, and the like.
[0028] Also, or alternatively, the CPU could be connected to a vehicle based wireless router 73 , using for example a WiFi 71 transceiver. This could allow the CPU to connect to remote networks in range of the local router 73 .
[0029] In addition to having exemplary processes executed by a vehicle computing system located in a vehicle, in certain embodiments, the exemplary processes may be executed by a computing system in communication with a vehicle computing system. Such a system may include, but is not limited to, a wireless device (e.g., and without limitation, a mobile phone) or a remote computing system (e.g., and without limitation, a server) connected through the wireless device. Collectively, such systems may be referred to as vehicle associated computing systems (VACS). In certain embodiments particular components of the VACS may perform particular portions of a process depending on the particular implementation of the system. By way of example and not limitation, if a process has a step of sending or receiving information with a paired wireless device, then it is likely that the wireless device is not performing the process, since the wireless device would not “send and receive” information with itself. One of ordinary skill in the art will understand when it is inappropriate to apply a particular VACS to a given solution. In all solutions, it is contemplated that at least the vehicle computing system (VCS) located within the vehicle itself is capable of performing the exemplary processes.
[0030] A vehicle used for typical consumer purposes spends most of its time turned off, and temperature and state-of-charge (SOC) are critical to lithium ion battery life during this time. The following functions describe the growth of resistance and the fade of capacitance at various states of charge. The functions demonstrate that a fully charged battery grows significantly in resistance over time and fades significantly in capacity, as compared to, for example, a battery kept at a 20% SOC.
[0000] Resistance Growth at 100% SOC: R ( T ) 100 =4.0806 ×T 2 +52.049 T+ 972.52
[0000] Resistance Growth at 60% SOC: R ( T ) 60 =2.8591 T 2 −3.9611 T+ 538.71
[0000] Resistance Growth at 20% SOC: R ( T ) 20 =1.6184 T 2 +8.9448 T+ 102.22
[0000] Fade at 100% SOC: F ( T ) 100 =4.0806 T 2 +52.049 ×T+ 972.52
[0000] Fade at 60% SOC: F ( T ) 60 =2.8591 T 2 −3.9611 ×T+ 538.71
[0000] Fade at 20% SOC: F ( T ) 20 =1.6184 T 2 +8.9448 T+ 102.22
[0031] Three functions of damage with respect to temperature can be derived:
[0000] D ( T ) 100 =αR ( T ) 100 +βF ( T ) 100
[0000] D ( T ) 60 =αR ( T ) 60 +βF ( T ) 60
[0000] D ( T ) 20 =αR ( T ) 20 +βF ( T ) 20
[0032] Assuming that the random temperature variable is expressed as a Weibull function, T, λ and K are output from the Black Box Model, the variable P represents the likelihood that the temperature is less than T.
[0000]
P
(
T
;
λ
;
K
)
cdf
=
K
λ
(
T
λ
)
K
-
1
-
(
T
λ
)
K
[0033] The likelihood that the battery damage will be less than a particular value is estimated as follows. Three temperature values are computed for the mean, mean plus standard deviation and mean minus standard deviation (μ, μ+σ, μ−σ) because they are easy to compute. For the Weibull function the equations follow:
[0000]
μ
=
λΓ
(
1
+
1
K
)
,
σ
=
λ
2
Γ
(
1
+
2
K
)
-
μ
2
[0034] Where μ and σ are in units of temperature.
[0035] Next D(T) 100 , D(T) 60 , D(T) 20 are computed for T=μ, T=μ+σ, T=μ−σ giving D(μ) 100 , D(μ+σ) 100 , D(μ−σ) 100 , D(μ) 60 , D(μ+σ) 60 , D(μ−σ) 60 , D(μ) 20 , D(μ+σ) 20 , D(μ−σ) 20 . From the three D 100 values the Weibull variables λ and k for D 100 , so the cumulative distribution function for the random variable D 100 will have the same form as that for temperature (T) as shown above.
[0000]
P
(
D
100
;
λ
;
K
)
cdf
=
K
λ
(
D
100
λ
)
K
-
1
-
(
D
100
λ
)
K
[0036] Similar equations can be made for D 60 , D 20 so that D 100 , D 60 , D 20 can be expressed as random variables.
[0037] To develop a real function for damage from both T and SOC, three equations are used at the onset:
[0000] D ( T ) 100 =αR ( T ) 100 +βF ( T ) 100
[0000] D ( T ) 60 =αR ( T ) 60 +βF ( T ) 60
[0000] D ( T ) 20 =αR ( T ) 20 +βF ( T ) 20
[0038] A quadratic interpolation function is developed as follows:
[0000] D ( T,S )= AS 2 +BS+C
[0039] Where A,B,C are determined by solving the following matrix equation.
[0000]
[
D
(
T
)
100
D
(
T
)
60
D
(
T
)
20
]
=
[
100
2
100
1
60
2
60
1
20
2
20
1
]
[
A
B
C
]
[0040] If T is computed as a random variable from the black box, D(T,S) can be computed as a random variable as is described in another figure in which D(T) is computed as a random variable.
[0041] The black box represents a forecast of the temperature as it varies in time as a time series of T values for each time interval. The parking space ranking module converts the time series into damage series and has algorithms for estimating total damage for the expected parking time window and distance from the final objective. In one example, it determines which parking spots have the best value during the time interval so the driver can be directed to those spots.
[0042] Operation of a battery cooling system while the vehicle is turned off can help keep the battery cool and a low state of charge can be maintained until shortly before the vehicle is needed. This is a good way to maximize battery life if charging is available. When charging not available, which is frequently the case, choosing a cool parking location and maintaining as low a state of charge as possible are the best strategy, but difficult to do in practice (since future temperature and/or shade conditions are often not known).
[0043] It can be very difficult to predict the temperature of a parking space during the interval in which a vehicle is expected to park there because there are many unknown temperature-affecting factors. If the space is in the open, the sun is high and the weather clear, it will be hot during the day but likely cool at night. So this would be a good place to park at night, but a bad place during the day. If the space is shaded under the same conditions it may be cooler during the day but warmer at night. The situation varies under cloudy conditions, windy conditions, etc., making it difficult for a driver to incorporate into their parking decisions.
[0044] An application program running on a VCS platform and, for example, incorporated into a social network content delivery network, and which further has access to vehicle sensors, can be used to help the driver locate an optimal parking space and the vehicle to implement an SOC strategy. The application will use back-end services from a weather provider to provide data that is unavailable from vehicle sensors and from a map provider for data unavailable on the vehicle. Of course, neither the social network nor the vehicle sensors are necessary, as the application could simply pull all relevant data from a cloud server.
[0045] The application may include two phases if sensors are available, a data gathering and sharing phase and parking strategy phase. The parking strategy phase may include an advisory feature and a state-of-charge management feature.
[0046] In the data gathering and sharing phase, vehicle sensors are used to collect location information from parked vehicles and any weather related information that is available such as, but not limited to, temperature, time of day, date, humidity, barometric pressure and solar heating. This data is augmented with data available from back-end weather services to provide meteorological data such as wind speed and direction. All the meteorological data is used to train a black-box model for predicting the temperature at the location of the parked vehicle. Other vehicles that park in the same location also contribute to the training of the black-box model. The black box model may be implemented as a software module and in the content delivery network.
[0047] As a vehicle enters the parking area, the driver informs the application, via a human-machine interface (HMI), for example, of the final destination, the time interval the vehicle is expected to be parked, and information relating to how far the vehicle must travel after parking to reach the next charging location. The application then combines known parking locations acquired from historical locations of parked vehicles with the locations of currently parked vehicles and applies the black-box model to determine a set of vacant parking spaces close to the final destination with favorable temperature profiles. The human-machine interface can then be used to direct the driver to these preferred parking locations.
[0048] Once parked, the black-box model of the selected parking space is combined with the weather forecast from the back-end weather service to produce a temperature forecast for the parking space. The minimum battery state of charge requirement is determined using the next charge location provided by the driver and a distance to empty calculation. The battery control system then implements a strategy for cooling the battery using excess battery state-of-charge that takes the battery down to the minimum state-of-charge while cooling during the most damaging portions of the parking interval.
[0049] FIG. 2 shows an illustrative process for data gathering. In this illustrative example, the process will engage in data gathering at any number of vehicles that have the appropriate sensors provided thereto. By using this crowd-sourced data, models for actual temperature profiles associated with various parking spots on various days of the year under various current weather conditions (current for the time when the data was gathered) can be determined.
[0050] In this example, once the vehicle is parked at a location, data gathering can begin 201 . This illustrative example engages in data gathering for some or all of the time the vehicle is parked in the location. In this example, because data gathering is ongoing, the process first checks a last data point gathered (if any) 203 to determine if it is time to gather new data 205 . For example, data may be gathered every five minutes, every half hour, etc.
[0051] If new data is needed, the process will engage any number of appropriate vehicle sensors 207 . These can be, for example, without limitation, humidity, temperature, ambient light, wind speed, etc. sensors. Data is gathered from the accessed and engaged sensors 209 and the data is saved locally 211 . At some point, when a connection to a remote system is available 213 , the process will upload the data to the remote system 215 . This data can then be used to build both a local temperature/weather profile (for use in this and possibly other concepts) and a model for the current parking space under current weather conditions on the current day/time of year.
[0052] A relatively few number of vehicles can gather a rather significant amount of data about parking space characteristics in a relatively short period (a few months or a year or two) of time. This data can be used to profile the parking spaces and used, in the future, to recommend which parking spaces should be utilized under which weather conditions at which times. Also, parking spaces sharing similar characteristics in a similar area of the country can be assumed to have relatively similar profiles, so some measure of extrapolation can be used to quickly model spaces for which data is unavailable or for which limited data is available (e.g., an uncovered, un-shaded parking space in one location is probably similar in characteristics to another, similarly situated space a half mile away).
[0053] FIG. 3 shows an illustrative process for further data gathering. In this example, the process receives vehicle data over some time period (reported periodically or when a vehicle is driven out of a space) 301 . The process then contacts a weather data provision service 303 , which stores weather data for the day, for example. Weather data, for the location at which the vehicle was/is parked, and for the duration of the parking, is obtained from the service 305 .
[0054] This data can then be correlated to noted sensor data from the vehicle, to further determine characteristics of the parking space 307 . A model of the particular parking space can then be adjusted as appropriate 309 .
[0055] FIG. 4 shows an illustrative process for parking location recommendation. In this illustrative example, a driver will be provided with recommendations for parking a vehicle, based on current weather conditions, time of day, and observed or extrapolated characteristics of local parking locations.
[0056] The process checks a current vehicle location 401 to determine if the vehicle is proximate to a known destination 403 . If the vehicle is not at/near the destination, the process checks to see if the vehicle is in a parking lot 405 . This may be relevant, because the vehicle may be stopping on the way to an eventual destination. If the vehicle is not in a parking lot, the process also checks to see if the vehicle is in park 407 , which may also indicate an intent to stop for some time period.
[0057] If any of these conditionals apply, the process obtains information from the driver on how long of a stay is intended 409 . This information could also be “guessed” by a vehicle, based on a business at which the vehicle is currently present (charging station, restaurant, etc.). The process also attempts to obtain vacancy information for known, local parking locations 411 . This can be done by checking which known vehicles are currently parked at the present location, for example. Of course, the more vehicles that are on a network, the more accurate this data will be.
[0058] Based on assumed to be available parking, or at least, avoiding spaces known to be in use, the process may suggest parking spots or general areas where optimal battery life preservation characteristics are environmentally present 413 . Once an area is accepted by a driver 415 , the process may further suggest the “best” spots in the area 417 .
[0059] FIG. 5 shows an illustrative charging process, incorporating battery life preservation. This strategy employs the known or projected characteristics of the space, along with knowledge about a driver's continuing journey, to optimize a cooling strategy for a battery.
[0060] In this example, based on current weather, time of day and time of year, and known or projected characteristics of a space, the process obtains a space profile forecast 503 . This can be for the duration of the driver's stay, so that a proper cooling strategy can be implemented.
[0061] The vehicle will also determine a minimum charge needed to complete the journey 505 , so that the driver does not return to a vehicle, only to find the charge depleted beyond usefulness. Care can be taken in this determination such that a minimum drivable distance (e.g., 30 miles) always is preserved, no matter what. Then, in this example, the process determines an optimal cooling strategy, based on the amount of charge that can be used to cool the battery, along with the space forecast 507 . This and other strategies can also be obtained by the vehicle remotely, from a similar process running on a remote server (which may have greater data-access and processing power). The cooling strategy is then implemented for the duration of the vehicle's stay, as appropriate.
[0062] FIG. 6 shows a further illustrative charging process, incorporating battery life preservation. Here, a trip may have multiple destinations associated therewith. Accordingly, a more comprehensive cooling strategy may be more appropriate, and the charge will need to be sufficient to travel to all known destinations. Additional destinations along a route are determined 601 , as well as a known, preferred charging location (e.g., home, a certain station, etc.) 603 .
[0063] The process also determines a distance to empty 605 and, based on this information, what level of excess power remains for usage in a cooling strategy 607 . This information is integrated with a forecast for the entire route, along with likely parking for the entire route 609 to profile parking and weather for the whole route. A cooling strategy is then implemented for the whole journey.
[0064] For example, if a vehicle is to travel to a parking garage for two hours and then to an open mall parking lot for two hours, and only two hours of power to cool the battery remains, the process may wish to save this power for when the vehicle is in the open, presumably hotter, mall parking lot. In this manner, a comprehensive entire-route strategy can serve to better preserve vehicle battery life.
[0065] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. | 4y
|
CROSS-REFERENCE TO RELATED APPLICATION
Under 35 U.S.C. §119, this application claims priority to, and the benefit of, U.S. Provisional Patent Application entitled, “Wakeup Frame for Wireless LAN,” having Ser. No. 60/930,185, filed on May 15, 2007, which is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present disclosure generally relates to wireless communications and more particularly relates to systems and methods for communicating with stations in standby mode in an encrypted environment.
2. Background Information
Among other things, FIG. 1 illustrates a typical network configuration for communicating data between stations via an access point in a wireless local area network (WLAN) or 802.11-based network. As illustrated in the non-limiting example of FIG. 1 , a network 140 may be coupled to access points 130 and 132 . In some embodiments, the network 140 may be the Internet, for example, and can be connected to an external computer such as central computer 150 . Access point 130 can be configured to provide wireless communications to various wireless devices or stations 110 , 120 , 124 . Furthermore, access point 132 can be configured to provide wireless communications to various wireless devices or stations 112 , 114 and 116 . Depending on the particular configuration, stations 110 , 112 , 114 , 116 , 120 , and 124 may be a personal computer (PC), a laptop computer, a mobile phone, a personal digital assistant (PDA), and/or other device configured for wirelessly sending and/or receiving data. Furthermore, access points 130 and 132 may be configured to provide a variety of wireless communications services, including but not limited to: Wireless Fidelity (WIFI) services, Worldwide Interoperability for Microwave Access (WiMAX) services, and wireless session initiation protocol (SIP) services. Furthermore, the stations 110 , 120 , 124 may be configured for WIFI communications (including, but not limited to 802.11, 802.11b, 802.11a/b, 802.11g, and/or 802.11n).
Access point 130 , for example, periodically broadcasts a beacon frame to various stations at a beacon period. The beacon frame is used by an access point to announce its presence and to relay information. For example, if station 110 is a laptop and is powered up or is transported to a location within range of access point 130 , station 110 listens for a beacon frame from all access points in its range. Each access point within range transmits a beacon frame and depending on the system, the user at station 110 can select which access point to use, thereby making an association between station 110 and the access point.
In order to save power, stations can be put into standby mode or a deep sleep mode. Also, for the purposes of this disclosure the term “sleep mode” will be taken to mean an operating state entered by a computing device either upon initiation by a user or after expiration of a period of sufficient inactivity in which the amount of power supplied to the device is reduced as compared to the amount supplied during normal operation.
Due in part to the dynamic technology dependent nature of today's workplace, network administrators must constantly perform functions requiring access of individual network nodes from the administrator's computer. These functions can include configuring new nodes, updating and installing software, adding network printers, scanning for viruses, and file back-ups to name a few. Typically, many of these administrative functions are scheduled for execution after normal business hours so as to minimize interference with user applications during the work day. However, during these after hour times, individual computers on the LAN may be in one of a variety of power conserving modes, also known as sleep modes. Typically, the power conserving modes cause the display to be put in a low power state, the hard drive to be spun down and even the microprocessor to reduce its clock frequency or to be shut down completely. In the case where the computers are actually stations on a WLAN, the antenna and the radio frequency (RF) circuitry are shutdown or put into a power saving inactive mode. Having the computers powered down can make it difficult if not impossible to schedule and implement after hours network events. If the administrator has to physically turn on each machine, the efficiencies of centralized network administration are lost.
In another set of circumstances, if the wireless station has enabled a phone function perhaps in a voice over IP (VoIP) setting, the station may need to wake up to receive the call.
In U.S. patent application Ser. No. 10/995,188, filed Nov. 24, 2004, entitled “Systems and Methods for Wireless Wake-On-LAN for Wireless LAN Devices,” a wakeup data sequence is broadcast by an access point to all stations. Each station periodically wakes up and receives the wakeup data sequence, if present. The wakeup data sequence identifies which stations need to wake up. If a station receives the wakeup data sequence, but is not identified, it returns to standby mode.
When a station goes into standby mode, it is disassociated with the access point. In a protected environment, such as when Wired Equivalent Privacy (WEP) is used, the frame body of all data frames from the access point is encrypted. Because a station in standby mode is disassociated, it cannot decrypt data frames from the access point. The station will not be able to decrypt the body of a wakeup data sequence as broadcast by the access point. So even if the station were able to determine that there was a wakeup data sequence broadcast by the access point, the station could not decode the frame body and hence would not know which stations need to wake up. Accordingly, various needs exist in the industry to address the aforementioned deficiencies and inadequacies.
SUMMARY OF INVENTION
The methods and systems described herein can be used to address the aforementioned deficiencies. One embodiment of a method and system relies on an access point distinguishing a particular reserved multicast destination address as for disassociated or unencrypted communications. When an access point receives a multicast transmission addressed to the reserved multicast destination address, the access point will not encrypt the transmission regardless of whether the access point is functioning in a protected mode. As a counterpart, the station will recognize that even though the WLAN is protected and the station is disassociated, a multicast on the reserved address will be unencrypted and may contain a message it is interested in. In particular, the message could be a wakeup message specifying which station needs to wake up and reassociate.
In another embodiment, an external system transmits a message over reserved multicast address, but encodes the message through the length of the payload, so that even if the multicast transmission is encrypted, a disassociated station can decode the message from the payload length. Because there are length limitations on frame size, various methods can be used to distribute a message over a sequence of frames. Again the message could be an instruction for a disassociated station to wake up and reassociate.
In both embodiments, a reserved multicast address can be agreed upon by a convention such as specification by a standards body such as by Institute of Electrical and Electronics Engineers (IEEE). Furthermore, both methods are interoperable with an unprotected environment.
Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF DRAWINGS
Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 illustrates a typical network configuration for communicating data between stations via an access point in a WLAN or 802.11-based network;
FIG. 2 illustrates an embodiment of one of the wireless devices/stations shown in FIG. 1 ;
FIG. 3 illustrates an embodiment of one of the access points shown in FIG. 1 ;
FIG. 4 shows the format for a data frame;
FIG. 5 shows how the payload length can be related to a station;
FIGS. 6A-D illustrate a multiple frame approach that can be used;
FIG. 7 is a flowchart describing the method of encoding a message based on the approach of FIGS. 6A-D ;
FIG. 8 is a flowchart describing the corresponding method of decoding a message encoded in accordance with FIG. 7 ;
FIGS. 9A-C show a multiplicative approach where each payload length encompasses eight values representing three bits of information; and
FIGS. 10A-10C show a multiplicative approach where each payload length encompasses eight values representing three bits of information, and the first payload of the first frame represents the number of subsequent frames required to encode the message.
DETAILED DESCRIPTION
A detailed description of embodiments of the present invention is presented below. While the disclosure will be described in connection with these drawings, there is no intent to limit it to the embodiment or embodiments disclosed herein. On the contrary, the intent is to cover all alternatives, modifications and equivalents included within the spirit and scope of the disclosure as defined by the appended claims.
FIG. 2 illustrates an embodiment of one of the wireless devices/stations shown in FIG. 1 . It can be configured to receive and process messages as disclosed below. Generally speaking, station 120 can comprise any one of a wide variety of wireless computing devices, such as a desktop computer, portable computer, dedicated server computer, multiprocessor computing device, cellular telephone, PDA, handheld or pen based computer, embedded appliance, and so forth. Irrespective of its specific arrangement, station 120 can, for instance, comprise memory 212 , processing device 202 , a number of input/output interfaces 204 , wireless network interface device 206 , display 208 , and mass storage 222 , wherein each of these devices is connected across one or more data buses 210 . Optionally, station 120 can also comprise a network interface device 220 also connected across one or more data buses 210 .
Processing device 202 can include any custom made or commercially available processor, a central processing unit (CPU) or an auxiliary processor among several processors associated with the computing device 120 , a semiconductor based microprocessor (in the form of a microchip), a macroprocessor, one or more application specific integrated circuits (ASICs), a plurality of suitably configured digital logic gates, or generally any device for executing instructions.
Input/output interfaces 204 provide any number of interfaces for the input and output of data. For example, where station 120 comprises a PC, these components may interface with user input device 204 , which may be a keyboard or a mouse. Where station 120 comprises a handheld device (e.g., PDA, mobile telephone), these components may interface with function keys or buttons, a touch sensitive screen, a stylist, etc. Display 208 can comprise a computer monitor or a plasma screen for a PC or a liquid crystal display (LCD) on a hand held device, for example.
Wireless network interface device 206 and optionally network interface device 220 comprises various components used to transmit and/or receive data over a network environment. By way of example, these may include a device that can communicate with both inputs and outputs, for instance, a modulator/demodulator (e.g., a modem), wireless (e.g., RF) transceiver, a telephonic interface, a bridge, a router, network card, etc. Station 120 can use wireless network interface device 206 to communicate with access point 130 .
With further reference to FIG. 2 , memory 212 can include any one of a combination of volatile memory elements (e.g., random-access memory (RAM), such as DRAM, and SRAM, etc.) and nonvolatile memory elements (e.g., flash, read only memory (ROM), nonvolatile RAM, etc.). Mass storage 222 can also include nonvolatile memory elements (e.g., flash, hard drive, tape, CDROM, etc.) Memory 212 comprises software which may include one or more separate programs, each of which includes an ordered listing of executable instructions for implementing logical functions. Often, the executable code can be loaded from nonvolatile memory elements including from components of memory 212 and mass storage 222 . Specifically, the software can include native operating system 214 , one or more native applications, emulation systems, or emulated applications for any of a variety of operating systems and/or emulated hardware platforms, emulated operating systems, etc. These may further include networking related software 216 which can further comprise a communications protocol stack comprising a physical layer, a link layer, a network layer and a transport layer. Network related software 216 can be used by processing device 202 to communicate with access point 130 through wireless network interface 206 and can further include logic that causes the processor to receive instructions from an access point while disassociated with access point 130 . In particular, the software can receive a wakeup instruction from the access point even in a protected wireless network. The software can comprise logic that maps the length of encrypted payloads of protected frames into a message. It should be noted, however, that the logic for performing these processes can also be implemented in hardware or a combination of software and hardware. One of ordinary skill in the art will appreciate that the memory 212 can, and typically will, comprise other components which have been omitted for purposes of brevity.
FIG. 3 illustrates an embodiment of one of the access points shown in FIG. 1 . It can be configured to receive and process messages as disclosed below. Generally speaking, station 120 can comprise any one of a wide variety of network functions, including network address translation (NAT), routing, dynamic host configuration protocol (DHCP), domain name services (DNS) and firewall functions. Irrespective of its specific arrangement, the stations 120 can, for instance, comprise memory 312 , a processing device 302 , wireless network interface 304 , network interface 306 , and nonvolatile storage 324 , wherein each of these devices is connected across one or more data buses 310 .
Processing device 302 can include any custom made or commercially available processor, a CPU or an auxiliary processor among several processors associated with access point 130 , a semiconductor based microprocessor (in the form of a microchip), a macroprocessor, one or more ASICs, a plurality of suitably configured digital logic gates, or generally any device for executing instructions.
Wireless network interface device 304 and network interface device 306 comprise various components used to transmit and/or receive data over a network environment. By way of example, either interface may include a device that can communicate with both inputs and outputs, for instance, a modulator/demodulator (e.g., a modem), wireless (e.g., RF) transceiver, a telephonic interface, a bridge, a router, network card, etc. Access point 130 typically uses wireless network interface device 304 to communicate with nearby stations, and network interface device 306 to communicate with network 140 . In some implementation, the two devices can be combined into one physical unit.
With further reference to FIG. 3 , memory 312 can include any one of a combination of volatile memory elements (e.g., RAM, such as DRAM, and SRAM, etc.) and nonvolatile memory elements (e.g., flash, ROM, nonvolatile RAM, hard drive, tape, CDROM, etc.). Memory 312 comprises software which may include one or more separate programs, each of which includes an ordered listing of executable instructions for implementing logical functions. Often, the executable code and persistent configuration parameters can be loaded from nonvolatile memory elements including from components of memory 312 . Specifically, the software can include native operating system 314 , one or more native applications, emulation systems, or emulated applications for any of a variety of operating systems and/or emulated hardware platforms, emulated operating systems, etc. These may further include networking related software 322 which can further comprise a communications protocol stack comprising a physical layer, a link layer, a network layer and a transport layer. These may further include networking related software 316 which can further comprise a communications protocol stack comprising a physical layer, a link layer, a network layer and a transport layer. Network related software 316 can be used by processing device 302 to communicate with access point 130 through wireless network interface 306 and can further include logic that causes the processor to receive messages broadcast to a special multicast address and retransmit the messages to nearby stations in unencrypted form regardless of whether access point 130 is operating on a protected WLAN. It should be noted, however, that the logic for performing these processes can also be implemented in hardware or a combination of software and hardware. One of ordinary skill in the art will appreciate that the memory 312 can, and typically will, comprise other components which have been omitted for purposes of brevity.
FIG. 4 shows the format for a data frame. Fields 402 , 404 , 406 , 408 , 410 , 412 , 414 and 416 are collectively referred to as the media access control (MAC) header. Frame control field 402 is a two octet fixed field indicative of properties of the frame as defined by the particular standard. It comprises a bit which when set indicates the frame is protected. Duration/ID field 404 is a two octet fixed field which comprises either duration information or identification information depending on the frame use as defined by the particular standard. Address fields 406 , 408 , 410 , and 414 are used to specify various address parameters. Typically in a multicast or broadcast application, address field 406 which is the receiver address is set to a multicast or broadcast address. Address field 408 which is the sender address is usually set to the BSSID. Address field 410 which is the source address is set to the address of the sender of the frame. Address field 414 is optional and is not used in a typical multicast or broadcast application. Sequence control field 412 is a two octet fixed field which comprises a fragment number and a sequence number. The fragment number is used when a frame is fragmented to keep track of the fragments. The sequence number is incremented each time a station transmits a message. Quality of service (QoS) control field 416 is a two octet field used to carry QoS parameters.
After the MAC header, the data frame includes frame body 418 which contains the payload. Frame body 418 is encrypted as specified by the standard if the frame is protected. Finally, frame check sequence field 420 is a four octet fixed field indicative of the integrity of the frame. The specific integrity check is specified by the standard, but as an example, some standards use a cyclic redundancy code (CRC).
Referring to the architecture in FIG. 1 , central computer 150 located somewhere on network 140 needs to wake up station 110 . The central computer prepares a multicast message and transmits it to a multicast address. Access point 130 receives the multicast message addressed to multicast address and transmits it to stations within its range. If access point 130 is not a protected access point, then prior art methods to wake up station 110 could be used. However, if access point 130 is protected, if station 110 is in standby mode and disassociated with access point 130 , it cannot decrypt messages from access point 130 without reassociating with access point 130 which is costly in energy consumption as the station would have to roam and scan. Due to the cost in resources, it is desirable to reassociate only if access point 130 has traffic for station 110 . This results in a vicious circle, that is, a station should not reassociate unless traffic is waiting for the station, but the station cannot know if there is traffic waiting for the station unless it reassociates.
One solution uses a specially designated multicast address. Many multicast addresses are designated for many purposes. For example, some are used for broadcast of media. There are also multicast addresses that are designated for specific purposes. These special multicast addresses are typical designated by a standards body and are used for a specific purpose. For example, there is a multicast address that is used for the specific purpose of address resolution. For this solution, there could be a multicast address specifically for waking up disassociated stations or generally for communicating with disassociated stations. This address could be any multicast address agreed upon by convention or at least agreed upon by the central computer and the stations, but preferably would be an address that is designated with a special purpose. While for the purposes of this disclosure, this address will be referred to as the wakeup multicast address, it is understood that the address could apply to the more general purpose of communicating with disassociated stations.
In one embodiment, the access point upon receiving a multicast request through a network from a central computer, recognizes the destination address as a wakeup multicast address, that is, address frame 406 contains the wakeup multicast address. Rather than encrypting the payload and transmitting a multicast data frame, the access point creates a multicast frame without encrypting the payload. A station in standby mode wakes up and checks the multicast frames. This wake up can take place periodically at predetermined times, such as in the usually broadcast and multicast opportunity that occurs after a delivery traffic indication map (DTIM) beacon frame. When it sees a multicast frame with the destination address matching the wakeup multicast address, it recognizes the frame as a special multicast frame that is designated for disassociated stations. The station recognizes that the payload is not encrypted and can read the message. If the message is a wakeup message, the station can determine if it must wake up from the payload of the wakeup message. If so, the station reassociates with the access point and can now receive encrypted data designated for it. If the station determines it is not the intended recipient of the wakeup message, it can return to standby mode.
One drawback of this embodiment is that the access points must be aware of the wakeup multicast address and conditionally apply encryption not to data frames destined for the wakeup multicast address. This would require the APs to be upgraded. This amounts to requiring an upgrade in the infrastructure. While this may be done through software/firmware updates. It is likely a change in the standards would need to be established to implement this approach. Thus, it is desirable to have a solution where only the stations and the central computer need to be aware of the wakeup multicast frame, because such a solution would not require any infrastructure changes to be made.
In another embodiment, a central computer transmits a multicast message to the access point. The payload of the message is a dummy message, however, the length of the payload is indicative of the station or group of stations to wake up, or in general the length of the payload is a message or part of a message to be transmitted to one or more disassociated clients. The central computer sends the message to all connected access point(s) with the wakeup multicast address as the destination. In the example of FIG. 1 , central computer 150 would broadcast the wakeup message to access points 130 and 132 . The access point(s) receives the message but only recognizes the message as destined to a multicast address and not necessarily a multicast address with a special purpose. The access point encrypts the payload and transmits the multicast frame. When the station then receives the frame, it recognizes the wakeup multicast address and determines the length of the payload. Depending on the implementation, the payload size may exclude header and encryption information added by the access point to encrypt the payload. In this manner, the central computer does not need to be aware of the added length created by the encryption process. The length can then be mapped to a station or group of stations for which the wakeup message is intended.
The payload length can typically be varied between the order of 0 and 1500 Bytes, or between 64 and 1500 Bytes when the minimum Ethernet packet size is taken into account, or between 8 and 1500 Bytes when the Logical Link Control/Subnetwork Access Protocol (LLC/SNAP) header is taken into account (which is always present in 802.11 frames), or between 28 and 1500 if the wakeup message is sent as an IP packet (the IP header is 20 Bytes, plus 8 for the LLC/SNAP header). Therefore, to be more agnostic to the higher protocol layers, a range of 64 to 1500 should used.
For the sake of the specific examples, a minimum of 64 and a maximum of 1500 are used. The use of these values should in no way be construed to limit the embodiments to this value.
There are several approaches to mapping the payload length to a station. The most basic is to take the length and subtract the minimum length to obtain the index. For example, as depicted in FIG. 5 , suppose the payload length is 121 and by convention the agreed minimum length is 64, then station 57 (121−64) should wake up, where station 57 is the 57 th entry in a station list.
Another approach is to map the MAC address through some function to yield a value between the minimum and maximum length. For example, the length can be associated with 64+MAC address MOD 1436 to yield a length between 64 and 1500. This runs the risk that by coincidence more than one station maps to the same length. Under this situation, a station may awaken and reassociate unnecessarily. As the odds of this happening should be small, this mapping may be preferable as it eliminates the need to keep track of and maintain stations list. Although the odds of coincidentally two stations on the same network being mapped to the same length should be remote, due to commonalities in the portions of the MAC addresses, for example, there is a portion unique to each manufacturer, the probabilities may not be as remote. This can be resolved by first running the MAC address through a cryptographic hash. Thus, in the example above, the length is associated with 64+hash (MAC address) MOD 1436.
FIGS. 6A-D illustrate a multiple frame approach that can be used in the unlikely event 1436 values is not sufficient to convey the message to the desired station. The minimum length 64 is reserved as a continuation symbol. While the choice of the minimum length as a continuation symbol is used here, it is understood that equivalently any symbol between the minimum length and the maximum length could be used. FIGS. 6A and 6B illustrate representations of values from 1 to 1435. The mapping is similar to that given above except the minimum is set to 65 because the length 64 is reserved. FIG. 6A shows the representation of the value 57. FIG. 6B shows the representation of the value 1435. FIG. 6C illustrates how the value 1436 can be represented as 1436 is too large to be represented in a single frame. Two frames are required. As the value is greater than 1435, the first frame payload has a length of 64 which represents a continuation in counting from 1435 in the next frame payload. The length of the next frame payload is 65 which boils down to an offset value of 1, but since the frame is a continuation frame, the value is 1435 plus the offset value. FIG. 6D illustrates the representation of the value 1600. Again since the value 1600 is greater than 1435, a second frame is needed. Frame 1 would comprise a payload of length 64 and frame 2 a payload of length 1600−1435 plus the 64 minimum that is 229. The process could be extended to a third frame if the value to be represented is greater than 2870, and so on. However, with the use of multiple frames it can be more efficient to set a smaller maximum value rather than 1500 and use more frames. For strings of more than two frames, a specific length value could be designated to demarcate the beginning of a sequence.
FIG. 7 is a flowchart describing the method of encoding a message based on the approach of FIGS. 6A-D . The message in question is encoded as a number. One of ordinary skill in the art would recognize the equivalence between a message and its representation as a number. Notationally, the number M is initially the representation of the message, and a maximum payload length and minimum payload length are represented by l max and l min , respectively. Furthermore, to avoid cumbersome repetition in notation, the quantity l max −l min −1 will be referred to as the encoding range. The encoding process begins at step 702 , where M is compared to the encoding range. If M is less than the encoding range, a dummy payload is created with length M+l min +1 at step 704 , the payload can then be included in a protected frame possibly as part of a frame burst. This would end the encoding process. However, if M is greater than or equal to the encoding range, a dummy payload is created with length l min which can then be included in a protected frame possibly as part of a frame burst at step 706 . At step 708 , M is decremented by the encoding range. The process then repeats at step 702 .
FIG. 8 is a flowchart describing the corresponding method of decoding a message encoded in accordance with FIG. 7 . The same notation is adopted for clarity. As each frame is received perhaps within the same burst. Initially, M is set to zero at step 802 . At step 804 , the payload length from the next frame is derived shown as l payload . If l payload matches the continuation symbol which is l min in this example at step 806 , then M is incremented by the encoding range at step 810 and the process repeats at step 804 . However, if l payload is not equal to the continuation symbol, the process ends after M is incremented by l payload −l min −1 at step 808 .
The multiple frame approach of FIGS. 6A-D is additive, that is, each additional frame gives the ability to address and add fixed number of values (e.g. an additional 1435 values). FIGS. 9A-C show a multiplicative approach where each payload length encompasses 8 values representing three bits of information. A ninth value can be used as an end of message symbol. This shorter format enables the transmission of more data using shorter messages. Specifically, in FIG. 9A , the value 411 which is 635 in octal needs to be expressed. The first frame has length 70 which corresponds to an offset of 6 from the minimum payload length, hence represents the octal digit 6 in the first digit of the octal value. The second frame has length 67 which corresponds to an offset of 3 from the minimum payload length, hence represents the octal digit 3 in the second digit of the octal value. The third frame has length 69 which corresponds to an offset of 5 from the minimum payload length, hence represents the octal digit 5 in the second digit of the octal value. Finally a fourth frame has length 72 which corresponds to an offset of 8 from the minimum payload length which represents the end of value symbol. Similarly, FIGS. 9B and 9C illustrate the formatting of the values 56 and 98, respectively.
In general, the multiplicative approach splits the message into pieces based on some numeric base, (e.g., base 8 in the previous example). While it is tempting for those skilled in the art to use a power of 2 for the base, any numeric base can be used. Each piece is then encoded by adding the minimum payload length as an offset. The message is then terminated by an end of message symbol.
Alternatively, rather than specifying an end of message symbol the first frame could contain the number of frames representing the message. The general approach is similar to that illustrated in FIGS. 9A-9C . The message is split into pieces based on some numeric base. However, rather than expressing an end of message symbol in the last frame of the encoded message, the length of the message in frames is encoded in the payload of the first frame. Examples that are counterparts to the examples of FIGS. 9A-9C are illustrated as FIGS. 10A-10C .
The drawback to the multiple frame approaches is that sequence of the frames need to be tracked to insure the right information is tracked, but can be tracked by the sequence control frame 412 .
While all the approaches above can transmit data to a disassociated station, the information rate for the amount of traffic generated is very low. The tradeoff between power usage, reassociation time and urgency of the message should be weighed. However, one of the most suitable uses is for breaking the encryption/reassociation dilemma by altering the station in standby mode to wake up, reassociate and receive an important encrypted message.
It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims. | 4y
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation Application of PCT Application No. PCT/JP2011/058104, filed Mar. 30, 2011 and based upon and claiming the benefit of priority from prior Japanese Patent Application No. 2010-084342, filed Mar. 31, 2010, the entire contents of all of which are incorporated herein by reference.
FIELD
Embodiments described herein relate generally to an electric vehicle control apparatus using a cooling unit.
BACKGROUND
In general, a permanent-magnet synchronous motor can efficiently utilize energy and generate less heat, compared with an induction motor, and can therefore be easily subjected to weight reduction. Therefore, demands for a permanent-magnet synchronous motor have been increasing in recent years.
Such a permanent-magnet synchronous motor needs to be controlled by applying a voltage from a VVVF inverter in accordance with a rotation position of a rotor of each permanent-magnet synchronous motor. Therefore, individual control corresponding to each permanent-magnet synchronous motor is required. Accordingly, a special VVVF inverter is provided for each permanent-magnet synchronous motor, and a gate control apparatus for controlling each VVVF inverter is provided (for example, see Jpn. Pat. Appln. KOKAI Publication No. 2004-143577).
Therefore, the number of control apparatuses increases in a conventional system which controls individually each permanent-magnet synchronous motor. Increase in size of the entire apparatus and increase in costs have caused problems. Therefore, “trolley control” of controlling a permanent-magnet synchronous motor in control units of two motors is introduced, and increase in size of the apparatus is reduced (for example, Jpn. Pat. Appln. KOKAI Publication No. 2009-72049).
FIG. 9 is a circuit diagram of an electric-vehicle control apparatus which introduces conventional trolley control. Line power is supplied to a first main circuit 200 and a second main circuit 300 through a current collector (pantograph) 100 , a high-speed breaker 101 , a charging-resistance shortcircuit switch 102 , a charging resistor 103 .
The first main circuit 200 comprises: a first opening contact device 104 ; a first filter reactor 105 ; an overvoltage limit circuit comprising a first overvoltage limit resistor 107 and a first overvoltage limit resistor switch 108 ; a first and a second direct voltage detector 109 a , 109 b ; a first and a second inverter filter capacitor 110 a , 110 b ; a VVVF inverter 111 a , 111 b forming a 2-in-1 inverter unit 120 a.
VVVF inverter 111 a for the permanent-magnet synchronous electric motor 115 a converts a power-line current as a direct current into an alternating current. The converted alternating current is supplied as a drive force to a permanent-magnet synchronous motor 115 a through a current sensor 112 a connected to a three-phase line, an electric-motor release contactor 113 a , and an electric-motor internal voltage detector 114 a . VVVF inverter 111 a and VVVF inverter 111 b are configured in the same manner as each other, and are connected in series with each other. The inverters form a 2-in-1 inverter unit 120 a and share one heat radiator.
The second main circuit 300 is configured in the same manner as the first main circuit 200 . The 2-in-1 inverter unit 120 a and 2-in-1 inverter unit 120 b are connected in parallel with each other. As a ground, a wheel 116 is connected to each of the 2-in-1 inverter unit 120 a and the 2-in-1 inverter unit 120 b.
FIG. 10 is a block diagram showing a gate control system of an electric-vehicle control apparatus shown in FIG. 9 . As shown in FIG. 10 , the 2-in-1 inverter unit 120 a is provided with an overvoltage-limit controller element 107 and a gate control apparatus 130 for controlling VVVF inverters 111 a and 111 b . The inverter unit 120 b is also configured in the same manner as above. In the figure, equal numerals surrounded by circles indicate that connection is made to each other. The power supply for the gate control apparatus (common controller 131 ) is provided for each set of 2-in-1 inverter units 120 a and 120 b.
The gate control apparatus 130 controls, by itself, VVVF inverters 111 a and 111 b and on/off of the overvoltage-limit control element 108 . Therefore, output currents detected by current sensors CTU 1 , CTW 1 , CTU 2 , and CTW 2 for VVVF inverters 111 a and 111 b , and an electric-motor internal voltage based on electric-motor internal-voltage detectors 114 a and 114 b are input to the gate control apparatus 130 .
The output of the 2-in-1 inverter unit 120 a is connected to each of the permanent magnet synchronous motors 115 a and 115 b . Control units depend on individual control methods. The release conductor 104 and filter reactor 105 are provided respectively for VVVF inverters 120 a and 120 b , and control units each are 2-in-1 inverter units for electric motors.
In a conventional electric-vehicle control apparatus for a permanent-magnet synchronous motor using a 2-in-1 inverter unit, a large number of semiconductor elements need to be equipped. For each 2-in-1 inverter unit, a filter reactor, an overvoltage limit resistor, and an overvoltage limit control resistor switch are provided. Therefore, a large number of components are used, which makes it difficult to reduce the size of the entire apparatus.
One embodiment has an object of providing an electric control apparatus capable of individually controlling a permanent-magnet synchronous motor and reducing the size of the entire apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a circuit configuration of the first embodiment;
FIG. 2 is an equivalent circuit diagram of a semiconductor device package according to the first embodiment;
FIG. 3 is a chart showing a voltage output and a temperature increase of a semiconductor device package according to the first embodiment;
FIG. 4 shows an exterior of the first embodiment;
FIG. 5 shows a circuit configuration of the third embodiment;
FIG. 6 shows a circuit configuration of the third embodiment;
FIG. 7 is a U-phase circuit configuration of a 3-level power conversion apparatus according to the fourth embodiment;
FIG. 8 is an exterior view of the 3-level power conversion apparatus according to the fourth embodiment;
FIG. 9 shows a conventional circuit configuration; and
FIG. 10 shows a conventional control configuration.
DETAILED DESCRIPTION
Various embodiments will be described hereinafter.
In general, according to one embodiment, there is provided an electric-vehicle control apparatus including: an inverter unit comprising a plurality of inverters each configured by a U-phase circuit, a V-phase circuit, and a W-phase circuit; and a cooling mechanism, the plurality of inverters provided on the cooling mechanism and sharing the cooling mechanism, wherein the U-phase, V-phase, and W-phase circuits each are configured as a semiconductor device package including two semiconductor switching elements contained in one package and in series.
Hereinafter, embodiments will be described with reference to the drawings.
First Embodiment
The first embodiment of the invention will be described with reference to the drawings.
FIG. 1 shows a circuit configuration of an electric-vehicle control apparatus of the first embodiment according to the present invention. FIG. 2 is an equivalent circuit diagram of a semiconductor device package according to the first embodiment. FIG. 3 is a chart showing a voltage output and a temperature increase of a semiconductor device package according to the first embodiment. FIG. 4 is an exterior view showing the first embodiment.
Configuration of 4-in-1 Inverter Unit
The circuit configuration of the electric-vehicle control apparatus according to the present embodiment comprises a first 4-in-1 inverter unit 1 , as shown in FIG. 1 . On a direct-current input side, a circuit of the first 4-in-1 inverter unit 1 is configured by a pantograph 4 , a high-speed breaker 5 , a charging-resistor shortcircuit contactor 6 , a charging resistor 7 , a release contactor 8 , a filter reactor 9 , an overvoltage limit resistor 10 , an overvoltage-limit switching element 11 , a wheel 12 , and a filter capacitor 14 . On an alternating-current-output-side, a circuit is configured by permanent-magnet-synchronous electric motors 2 ( 2 a , 2 b , 2 c , and 2 d ), motor release contactors 3 ( 3 a , 3 b , 3 c , and 3 d ), and electric current sensors 34 ( 34 a , 34 b , 34 c , and 34 d ).
The pantograph 4 is connected to the high-speed breaker 5 , which is connected to the charging-resistor-shortcircuit conductor 6 . The charging-resistor-shortcircuit conductor 6 is connected in parallel with the charging resistor 7 and in series with the release contactor 8 . The release contactor 8 is connected to the filter reactor 9 . The filter reactor 9 is connected to a positive direct-current terminal of the first 4-in-1 inverter unit 1 , and a negative direct-current terminal is connected to a wheel 12 . An overvoltage-limit serial circuit 19 configured by serially connecting the overvoltage limit resistor 10 and the overvoltage-limit-control switching element 11 is connected, at one terminal, to the filter reactor 9 and the positive direct-current terminal of the first 4-in-1 inverter unit 1 , and is connected, at another terminal, to the negative direct-current terminal of the first 4-in-1 inverter unit 1 and the wheel 12 . The filter capacitor 14 and the direct-current voltage sensor 15 each are connected in parallel on the direct current side of the first 4-in-1 inverter unit 1 . On the alternating current side of the first 4-in-1 inverter unit 1 , current sensors 34 a , 34 b , 34 c , and 34 d are provided on two lines among output three-phase lines. Connected to the alternating current side are four permanent-magnet synchronous motors 2 a , 2 b , 2 c , and 2 d through the motor release contactors 3 a , 3 b , 3 c , and 3 d.
The first 4-in-1 inverter unit 1 is configured by VVVF inverters 21 a to 21 d , and VVVF inverters 21 a to 21 d are connected in parallel with each other on the direct current side.
VVVF inverter 21 a is configured by a U-phase semiconductor device package 22 a , a V-phase-semiconductor device package 22 b , a W-phase-semiconductor device package 22 c , and an inverter filter capacitor 13 a . U-, V-, and W-phase semiconductor device packages 22 a to 22 c are connected in parallel with each other on the direct current side, and are connected in parallel with the inverter filter capacitor 13 a . VVVF inverters 21 b to 21 d each are configured in the same manner as VVVF inverter 21 a.
The configuration of the control system is the same as FIG. 10 , and each inverter 111 is controlled individually.
Configuration of Semiconductor Device Package
FIG. 2 is an equivalent circuit diagram of a semiconductor device package 22 . FIG. 3 shows a switching state of a semiconductor device in the semiconductor device package, and a temperature state of the semiconductor device package by switching thereof.
As shown in FIG. 2 , the semiconductor device package 22 is configured by a serial circuit of a positive element 24 a of an upper arm and a negative element 24 b of a lower arm. This serial circuit is connected in parallel to the capacitor 13 . The positive element 24 a of the upper arm is a parallel connection circuit of a switching element Tr 1 and a diode D 1 . The negative element 24 b of the lower arm is an parallel connection circuit of a switching element Tr 2 and a diode D 2 . A connection point 26 between the positive element 24 a and the negative element 24 b is connected to an output terminal, and an output voltage is thereby provided.
The switching element Tr 1 of the positive element 24 a is turned on, and the switching element Tr 2 of the negative element 24 b is turned off. Then, an output current is made flow to a load through the switching element Tr 1 and output terminal from a power line. Meanwhile, the switching element Tr 1 of the positive element 24 a is turned off, and the switching element Tr 2 of the negative element 24 b is turned on. Then, an output current is made flow from a load through the switching element Tr 1 and an output terminal to a negative power-supply side. By repeating such switching, the direct current power is converted into an alternating power.
FIG. 3( a ) shows a waveform of a switching voltage (gate signal) waveform of the positive element 24 a , and FIG. 3( b ) shows a switching voltage waveform of the negative terminal 24 b . FIG. 3( c ) is an output voltage waveform of a semiconductor device package 22 . FIG. 3( d ) is a graph showing a temperature increase of the positive element 24 a . FIG. 3( e ) is a graph showing a temperature increase of the negative terminal 24 b.
As shown in FIG. 3( d ), the temperature of the positive element 24 a increases when the positive element 24 a shown in FIG. 3( a ) is on. The temperature does not substantially change when the positive element 24 a is off. Therefore, the temperature of the positive element 24 a gradually increases as switching operation of on/off is repeated. As shown in FIG. 3( e ), the temperature of the negative element 24 b gradually increases as switching operation of on/off is repeated. Here, the on state of the positive element 24 a and the on state of the negative element 24 b are alternately repeated. Therefore, the entire heat generation of the semiconductor device package 22 is constant as shown in FIG. 3( f ).
The 4-in-1 inverter unit 1 is configured by packaging, into a unit, the four VVVF inverters 21 a to 21 d which use the semiconductor device package 22 as described for each phase. FIG. 4 shows an exterior of the first 4-in-1 inverter unit 1 thereof.
As shown in FIG. 4 , the first 4-in-1 inverter unit 1 is configured by providing four three-phase VVVF inverters 21 a to 21 d on one cooling mechanism 23 . VVVF inverters 21 a to 21 d are attached to a flat surface of a heat receiving plate 23 a forming part of the cooling mechanism 23 . To a surface of the heat receiving plate 23 a opposite to the flat surface to which VVVF inverters 21 a to 21 d are attached, a heat radiator 23 b forming the other part of the cooling mechanism 23 is connected.
Operation
The operation of the electric-vehicle control apparatus according to the present embodiment will be described.
In FIG. 1 , a direct current supplied from a power line through the pantograph 4 is supplied to the filter capacitor 14 through the high-speed breaker 5 which is normally on, the charging resistor 7 , the release contactor 8 which is also normally on, and the filter reactor 9 . A direct current flows through the capacitors 13 a to 13 d of the inverters connected in parallel with the filter capacitor 14 , and sufficient charges are stored. Then, the charging-resistor shortcircuit contactor 6 turns on, and the direct current from the power line is supplied to the first 4-in-1 inverter unit 1 through the high-speed breaker 5 , charging-resistor shortcircuit contactor 6 , release contactor 8 , and filter reactor 9 .
When the inverter filter capacitor 13 a - 13 d is fully charged and when direct-current line power is supplied to the first 4-in-1 inverter unit 1 , a direct current voltage is applied to semiconductor devices included in UVW-phase semiconductor device packages 22 a to 22 c in each of VVVF inverters 21 a to 21 d . The supplied direct power is converted into alternating current power by switching of the semiconductor elements. The converted alternating-current power is supplied to and started to drive the four permanent-magnet synchronous motors 2 .
In the present embodiment, for example, when the first 4-in-1 inverter unit 1 is applied with a power-line voltage of 1500 V, the same 1500 V is applied to each of VVVF inverters 21 a to 21 d . The voltage of 1500 V is applied to each of VVVF inverters 21 a to 21 d , a corresponding current to the voltage flows through the permanent-magnet synchronous motor 2 , and drives the permanent-magnet synchronous motor 2 .
Thus, the permanent-magnet synchronous motor 2 is driven by power conversion of converting direct-current power of the first 4-in-1 inverter unit 1 into an alternating-current power. However, power conversion loss occurs at the time of electric power conversion. The electric-power conversion loss is caused as heat from a semiconductor device. Generated heat transfers to the heat receiving plate 23 a , then transfers from the heat receiving plate 23 a to the heat radiator 23 b , and is radiated out of the heat radiator 23 b . That is, the heat generated by power conversion loss does not stay in the vehicle but is radiated to outside.
Further, if one VVVF inverter 21 malfunctions in the first 4-in-1 inverter unit 1 during work of the electric-vehicle control apparatus and if the control apparatus (not shown) detects the malfunctioning, all the four VVVF inverters 21 a - 21 d are released by releasing the high-speed breaker 5 ( FIG. 1 ).
Further, if the direct-current power sensor 15 detects excess of the direct-current voltage supplied to the first 4-in-1 inverter unit 1 by variation of the power-line voltage during work of the electric-vehicle control apparatus, the overvoltage-limit switching element 11 is turned on, thereby to consume the direct-current power by the overvoltage limit resistor 10 , and to remove an excess of the voltage. Thus, the overvoltage-limit switching element 11 is controlled to turn on/off, based on an output of the direct-current voltage sensor 15 .
Effects
In the electric-vehicle control apparatus configured in this manner, VVVF inverters 21 a to 21 d each having WW-phase semiconductor device packages 22 a to 22 c share the heat radiator 23 b . Therefore, a heat generation amount of the first 4-in-1 inverter unit 1 which contains VVVF inverters 21 a to 21 d is equalized over the entire unit, and can therefore be efficiently cooled. Further, if semiconductor elements are individually set on a heat radiator as in the conventional elements, a setting space for twenty four semiconductor elements is required. In the present embodiment, however, use efficiency of the cooler 23 improves and space saving can be performed, by using the device package 22 which contains two semiconductor devices so as to equalize the heat generation amounts of respective semiconductor devices. As a result of this, the 4-in-1 inverter unit in which twelve semiconductor device packages 22 are attached to the heat radiator 23 can be configured.
Further, the filter reactor 9 , overvoltage limit resistor 10 , overvoltage-limit switching element 11 are shared in one apparatus. Accordingly, the number of components is reduced, and the entire electric-vehicle apparatus can be made smaller.
Further, the direct-current voltage sensor 15 , current sensors 34 a to 34 d , and motor release contactors 3 a to 3 d can be contained in the 4-in-1 inverter unit 1 . In this case, a further effect of space saving is achieved, and wiring is simplified by containing a great number of components in a housing. Manufacture, placement, and maintenance of the entire apparatus can be facilitated.
Second Embodiment
The second embodiment of the invention will be described with reference to the drawings.
FIG. 5 shows a circuit configuration of the second embodiment. The same components as those in FIGS. 1 to 4 are respectively denoted at the same reference signs, and descriptions thereof will be omitted herefrom.
Configuration
The circuit configuration of the present embodiment differs from the circuit configuration of the first embodiment in that a different connection method is employed for VVVF inverters 21 a to 21 d forming the 4-in-1 inverter unit, and in that, on the direct-current side of each inverter 21 , the direct-current voltage sensor 32 and inverter filter capacitor 13 each are connected in parallel. In this respect, descriptions will now be made below.
A second 4-in-1 inverter unit 30 is configured by VVVF inverters 21 a to 21 d . VVVF inverters 21 a and 21 b connected in series form a serial inverter circuit 33 a . VVVF inverters 21 c and 21 d form a serial inverter circuit 33 b . The serial inverter circuits 33 a and 33 b are connected in parallel with each other.
On the direct-current side of VVVF inverter 21 a , the inverter filter capacitor 13 a and the direct-current voltage sensor 32 a are connected in parallel. VVVF inverters 21 c and 21 d have the same configuration as VVVF inverters 21 a and 21 b . The inverter filter capacitors 13 c and 13 d and the direct-current voltage sensors 32 c and 32 d are connected in parallel on the direct-current side.
Operation
The operation of the electric-vehicle control apparatus according to the present embodiment will be described.
In FIG. 5 , for example, when a second 4-in-1 inverter unit 30 is applied with a power-line voltage of 1500 V, the voltage of 1500 V is applied to each of the serial inverter circuits 33 a and 33 b . In each of the serial inverter circuits 33 a and 33 b , the power-line voltage of 1500 V is divided into two partial voltages. A voltage of 750 V is applied to each of VVVF inverters 21 a to 21 d , and a current corresponding to the voltage flows through a permanent-magnet synchronous motor 2 , and drives the permanent-magnet synchronous motor 2 .
At this time, the direct-current voltage sensor 32 a detects a direct-current-side voltage of VVVF inverter unit 21 a . Similarly, the direct-current voltage sensors 32 b to 32 c respectively detect direct-current-side voltages of VVVF inverter units 21 b to 21 d.
Effects
An effect of the electric-vehicle control apparatus according to the second embodiment is that the voltage applied to each of VVVF inverters 21 is a voltage obtained by dividing the power-line voltage by two. That is, switching of the semiconductor devices is performed at a lower voltage than the first embodiment. Therefore, heat generated as power conversion loss can be reduced. Since heat generation is reduced, the cooling mechanism can be made smaller, and energy can be saved during driving of the apparatus.
By detecting a direct-current-side voltage value of each VVVF inverter 21 by using the direct-current voltage sensor 32 . The inverters can be controlled more accurately.
Third Embodiment
The third embodiment of the invention will be described with reference to the drawings.
FIG. 6 shows a circuit configuration of the third embodiment. The same components as those in FIGS. 1 to 4 are respectively denoted at the same reference signs, and descriptions thereof will be omitted herefrom.
Configuration
The circuit configuration of the present embodiment differs from the circuit configuration of the first embodiment in that a different connection method is employed for VVVF inverters 21 a to 21 d forming a 4-in-1 inverter unit, and in that, on the direct-current side of each inverter 21 , a direct-current voltage sensor 40 and a filter capacitor 41 each are provided. In this respect, descriptions will be made below.
In FIG. 6 , a third 4-in-1 inverter unit 42 is configured by VVVF inverters 21 a to 21 d . VVVF inverters 21 a and 21 b connected in series form a parallel inverter circuit 43 a . VVVF inverters 21 c and 21 d form a parallel inverter circuit 43 b . The parallel inverter circuits 43 a and 43 b are connected in parallel with each other. On the direct-current side of VVVF inverter 43 a , the filter capacitor 41 a and the direct-current voltage sensor 40 a are connected in parallel. Similarly, the parallel inverter circuit 40 b is connected to each of the filter capacitor 41 b and the direct-current voltage sensor 40 b.
Operation
Next, operation of the present embodiment will be described.
In the present embodiment, for example, when a third 4-in-1 inverter unit 42 is applied with a power-line voltage of 1500 V, a divided voltage of 750 V is applied to each of the parallel inverter circuits 43 a and 43 b . When the parallel inverter circuits 43 a and 43 b each are applied with the voltage 750 V, the voltage of 750 V is applied to each of VVVF inverters 21 a to 21 d . A current corresponding to the voltage flows through a permanent-magnet synchronous motor 2 , and drives the permanent-magnet synchronous motor 2 .
Effects
The present embodiment can achieve the same effects as the first embodiment. That is, the voltage applied to each of VVVF inverters is a voltage obtained by dividing twice the power-line voltage. That is, switching of the semiconductor devices is performed at a lower voltage than the first embodiment. Therefore, heat generated as power conversion loss can be reduced. Since heat generation is reduced, the cooling mechanism can be made smaller, and energy can be saved during driving of the apparatus.
Since the direct-current side of parallel inverter circuits 43 a and 43 b are detected by direct-current voltage sensors 40 a and 40 b , the number of components can be smaller than the second embodiment.
Fourth Embodiment
The fourth embodiment of the invention will be described with reference to the drawings.
FIG. 7 is a circuit diagram of one of U, V, and W phases of 3-level power conversion apparatus according to the fourth embodiment. Hereinafter, this phase is referred to as a U-phase. FIG. 8 is an exterior view showing the fourth embodiment. The same components as those in FIGS. 1 to 4 are respectively denoted at the same reference signs, and descriptions thereof will be omitted herefrom.
Configuration
The fourth embodiment is a modification of a semiconductor device package 22 (2-level output) according to the first embodiment into a semiconductor device package 22 of a 3-level output, and is applied to the inverter unit. The modification will now be described below.
FIG. 7 shows a circuit configuration of the U-phase of the 3-level power conversion apparatus according to the present embodiment. This U-phase circuit comprises a first element 65 a , a second element 65 b , a third element 65 c , a fourth element 65 d , and a first clamp diode 69 a , and a second clump diode 69 b.
A serial U-phase circuit is configured by serially connecting the first element 65 a , second element 65 b , third element 65 c , and fourth element 65 d . The first clump diode 69 a and second clump diode 69 b are connected in series. An anode of the first clump diode 69 a is connected between the first element 65 a and the second element 65 b . A cathode of the second clump diode 69 b is connected between the third element 65 c and the fourth element 65 d . The first element 65 a and the third element 65 c are contained in the first U-phase semiconductor device package 66 a . The second element 65 b and fourth element 65 d are contained in the second U-phase semiconductor device package 66 d.
FIG. 8 is an exterior view of a power conversion apparatus according to the fourth embodiment.
In FIG. 8 , a first V-phase semiconductor device package 67 a , a second V-phase semiconductor device package 67 b , and a third V-phase semiconductor device package 67 c of a V-phase circuit 67 , a first W-phase semiconductor device package 68 a , a second W-phase semiconductor device package 68 b , and a third W-phase semiconductor device package 68 c of the W-phase circuit 68 are commonly configured in the same manner as the U-phase circuit 66 .
Next, the U-phase circuit 66 , V-phase circuit 67 , and W-phase circuit 68 are set on a heat receiving plate 23 a of the cooling mechanism.
As shown in FIG. 8 , the U-phase circuit 66 and the W-phase circuit 68 are provided on two sides of the heat receiving plate 23 a . The V-phase circuit 67 is provided between the U-phase circuit 66 and the W-phase circuit 68 . In the U-phase circuit 66 , a first U-phase semiconductor device package 66 a , a second U-phase semiconductor device package 66 b , and a third U-phase semiconductor device package 66 c are provided in this order from upside. In the V-phase circuit 67 , a first V-phase semiconductor device package 67 a , a second V-phase semiconductor device package 67 b , and a third V-phase semiconductor device package 67 c are provided in this order from upside. In the W-phase circuit 68 , a first W-phase semiconductor device package 68 a , a second W-phase semiconductor device package 68 b , and a third W-phase semiconductor device package 68 c are provided in this order from upside.
Operation
In the U-phase circuit 66 , when a semiconductor element performs switching for power conversion, inductances of the second element 65 b and the third element 65 c are the greatest. That is, heat generation from the second element 65 b and third element 65 c is the greatest. Next, a heat generation amount from the first element 65 a and fourth element 65 d is the greatest. A heat generation amount from the first clump diode 69 a and the second clump diode 69 b is the smallest. The same as described above also applies to the V-phase circuit 67 and W-phase circuit 68 . Therefore, a heat generation amount generated from the first semiconductor device package 66 a ( 67 a and 68 a as well) which contains the first element 65 a and the third element 65 c combined with each other is equal to a heat generation amount generated from the second semiconductor device package 66 b ( 67 b and 68 b as well). A heat generation amount from the third semiconductor device package 66 c ( 67 c and 68 c as well) which contains a first clump diode 69 a and a second clump diode 69 b combined with each other is lower than a heat generation amount generated from the first semiconductor device packages 66 a , 67 a , and 68 a and the second semiconductor device packages 66 b , 67 b , and 68 b.
Effects
The electric-vehicle control apparatus configured as described above is arranged so as to sandwich the third semiconductor device packages 66 c , 67 c , and 68 c between the first semiconductor device packages 66 a , 67 a , and 68 a and the second semiconductor device packages 66 b , 67 b , and 68 b . In this manner, the heat transferred to the heat receiving plate 23 a is made uniform throughout the entire heat receiving plate 23 a , and efficient cooling can be achieved by the cooling mechanism 23 . Further, the 3-level power conversion apparatus having a greater number of semiconductor elements can be made even smaller than in a conventional apparatus.
The semiconductor device package 22 can be applied not only to a 4-in-1 inverter unit in which four VVVF inverter units 21 are mounted on one cooling mechanism as shown in the first to fourth embodiments but also to a different configuration such as 2-in-1 inverter unit.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions. | 4y
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BACKGROUND OF THE INVENTION
The so-named guillotine shearing machine is a well-known tool. One blade, generally the upper one, is mobile and slides on runners which keep the movement rectilinear and transversal to the cutting plane. The blade is operated by cams or by hydraulic systems. Shearing machines used for cutting lengths of sheet metal, profiles, continuous moving bands, comprise a pair of drums between which the band passes, and radially set blades which meet at the shearing plane to cut through the moving piece.
The radial position of the blades obviously determines the angle they assume, which angle varies progressively during cutting. This means that the advantages of speed and simplicity in continuously cutting a moving band are to some extent adversely affected and the operation lacks that precision which can only be obtained with blades set perfectly perpendicular to the piece to be cut. The invention here described avoids these drawbacks at the same time offering considerable advantages as will now be explained.
SUMMARY OF THE INVENTION
Subject of the invention is a guillotine shearing machine, especially one for cutting continuous metal bands, wherein the opposing longitudinal blades translate parallel one to another along equal circular trajectories with parallel axes of rotation lying on the same geometrical plane. Blade movement is reciprocally synchronized. The phases in movement of one blade in relation to the other are such that one blade meets the other close to the shearing plane becoming progressively superimposed to make the cut.
The start of each cutting cycle, corresponding to a 360° rotation of the blades, is controlled in relation to certain speeds at which the band, or any other piece to be cut, and the blades move during the cycle, and at the most suitable instant for cutting off the desired length of the band.
Blade speed is adjusted according to that of the band to be cut in such a way that, when the cut is made, the speed of the cutting edge practically coincides with that of band movement. The blade is moved by means of a double pair of cranks for each of the two blades, one pair being situated at each end of the blade. The two cranks in each pair are connected by sprocket wheels with an idling sprocket wheel in between them.
The pairs of cranks at each end of the blade are connected by a longitudinal shaft to ensure synchronized movement, preferably by pairs of gears.
The drive shaft is preferably fixed to the upper crank of the lower blade, connected to the lower crank of the upper blade by a pair of sprocket wheels.
Synchronizing shafts between the pairs of cranks for each blade are respectively connected, by means of gears, to the sprocket wheel fixed to the upper crank of the lower blade, and to the sprocket wheel fixed to the lower crank of the upper blade.
Each blade is fixed at either end to two connecting rods respectively connected to the cranks forming either of the pairs that support each of the above blades at both ends.
The connecting rods of the upper blade support an elastic presser acting over the whole width of the translating band, at the moment when the blades meet, accompanying their movement and at the same time stabilizing their vertical position to hold the band relatively steady in relation to the blades that make the cut.
At the beginning of the cut, said elastic presser is in contraposition to a support of the band fixed to the lower blade close to the cutting edge. Therefore, close to the cut and while it is being made, said support causes that part of the band as yet uncut to be raised to the progressive level of the lower blade where it remains until completion of the cut extending from one longitudinal edge of the band to the other. In so raising the band by means of the support fixed to the lower blade, speed of the band and of the cutting edge of the lower blade round its circular trajectory are kept practically equal until completion of the cut.
The start of each shearing cycle to cut off the desired length of band, in each cycle, as well as regulation of blade rotation speed, in each cycle, according to the speed at which the band moves so that blade and band speeds shall be equal when the blade makes contact with the band, is operated automatically by an electronic control panel which memorizes the information received from sensors applied to the band and which, according to the speed of band movement and according to a program typed in on a keyboard or by some other means, has one or more shearing cycles carried out for cutting off one or more equal or different lengths of band, as desired.
The characteristics and purposes of the invention will be made still clearer by the following examples of its execution illustrated by drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 Guillotine shearing machine, subject of the invention, seen from the front.
FIG. 2 The same machine seen from the back.
FIG. 3 Cross section view of the same machine.
FIG. 4 Diagram to show blade movements.
FIG. 5 Explanatory view showing cutting of a band with upper and lower blades.
FIG. 6 Explanatory view showing the cut band.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The shearing machine, subject of the invention, comprises a base (10) and uprights (11), (12) connected at the top by the head (43). Each upright comprises in turn the side pieces (13), (14).
The upper (15) and lower (16) longitudinal blades are respectively supported by frames (17), (18), the upper one comprises the bushings (19)-(20) and the lower one comprises the bushings (23-26).
Said bushings house the rotatable pins (27), (28) and (29), (30) of the cranks (31), (32) and (33), (34) which determine the cutting movement of the blades.
The extremities of the frames (17) and (18) create a kind of connecting rod (39), (40) and (41), (42) for respectively connecting the pairs of cranks (31-32), (33-34), (35-36) (37-38).
The drive shaft (50) is fixed to the crank (33) and can rotate on the bearings (51), (52) mounted respectively on the sides (13) and (14) of the upright (11).
By means of the sprocket wheel (53) and the opposing sprocket wheel (54), said shaft is similarly fixed to the crank (32) of the upper blade.
By means of the sprocket wheels (55) and (56) with intermediate idling sprocket wheel (57), the crank (33) is fixed in its movement to the crank (34).
Therefore, by means of the pins (29) and (30) and the bushings (23) and (24), the pair of cranks (33) and (34) determine the movement of the lower blade (16) in synchrony with the second pair of cranks (37), (38) connected by the connecting rod (42) and by other gears similar to those already described for the first pair of cranks.
The crank (32) is connected to the crank (31) by means of the connecting rod (39) realized with the frame (17) and with the connecting rod (41) of the same frame, fixed to the bushings (21) and (22).
Therefore, the cranks (35) and (36) at the other end of the frame (17) for the blade (15) are also made to move by mechanisms substantially the same as those already described for the lower blade, as the shafts for the two pairs of cranks respectively, on either side of the upper blade, are connected one to another by sprocket wheels like those already described (55), (56) and (57) and of which, for the sake of simplicity, only the sprocket wheel (59) fixed to the shaft of the crank (32) is indicated.
Synchronization of movement of the pairs of cranks (33-34) and (37-38) for the lower blade, and (31-32), (35-36) for the upper blade is ensured by the two horizontal shafts (70) and (71) supported on bearings like (60), (61) placed on on the sides like (13) and (14) of the uprights (11) and (12). Each of the two shafts is connected to the drive shaft (50) by means of gears like (62), fixed to the shaft (70) that engage with the sprocket wheel (53) mounted, as already explained, on said shaft (50).
On the upright (12) the shaft of crank (37) supports another sprocket wheel, not shown in the drawing, that engages a pinion fixed to the other end of the shaft (70) and carries out the same functions as the gear (62).
Mechanisms similar to those already described connect the shafts to cranks (31) and (35) with the longitudinal shaft (71) for synchronizing movement of the pairs of cranks for the upper blade.
An elastic presser 80 is fixed to the connecting rods (39), (41) of the upper blade. A support 81 substantially levelled with the lower blade 16, is fixed to the connecting rods 40, 42 of the lower blade.
FIG. 4 clearly shows the movements made by the upper (15) and lower (16) blades in their various positions as these positions change (15 1 ), (15 2 ), (15 3 ) and respectively (16 1 ), (16 2 ), (16 3 ), due to movement of the cranks.
At each shearing cycle the blades start from and return to the upper resting points (15 1 ) and (16 1 ).
When they have reached positions (15 3 ) and (16 3 ), the blades travel together with the band, little by little increasing the amount of superimposition, as they approach their lower resting points (15) and (16), and thus generating the cut.
During the cut (FIG. 5) upper blade 15 passes from position 15 3 to position 15, while lower blade 16 passes from position 16 3 to position 16; superimposing itself on blade 15 and completing the cut begun on one side of the band when the blades were in position 15 3 and 16 3 . In the curve traced by lower blade 16 to pass from position 16 3 to position 16, band 90 is raised by support 81 (FIGS. 2 and 3), together with blade 16. Thus the band speed at the start of contact with blade 16 remains equal to the circumferential speed of blade 16 until the cut is complete, ensuring the precision of the cut. During this cut support 81 fixed to blade 16 coincides with presser 80 fixed to blade 15. In FIG. 5 it can be clearly seen that band 90, raised by support 81, which moves to 81', assumes position 90', corresponding to the start of the cut at point A. Because of the rotation of the blades to their respective positions 15 and 16, the cut from point A (FIG. 6) to point B is completed. The speed of band 90, identical to that of blade 16 and support 81 during the cut from A to B (FIG. 6) ensures that point A moves to A', and thus that the cut BA' is along a YY axis perfectly orthogonal to the XX axis of the band.
The start of each shearing cycle to cut off the desired length of band, as well as regulation of blade rotation speed in each cycle according to the speed at which the band moves, is operated automatically by an electric control panel which memorizes the information received from sensors applied to the band and which, according to the speed at which it moves, and to a program put in on a keyboard or by some other controls, operates one or more cutting cycles for detaching one or more equal or different lengths of band, as required. The advantages offered by the invention are evident.
To summarise, though the band is continually moving, clean and precise cuts can be obtained, in the desired lengths, with the blades remaining always parallel in their cutting movements even though their trajectories are circular, and therefore being always transversal to the piece to be cut.
Compared therefore with the shearing machines at present in use, cutting is done at a speed and with a degree of precision never before achieved.
As the applications of the invention have been described as examples only, not limited to these, it is understood that every equivalent application of the inventive concepts explained, and any product manufactured and/or in operation according to the characteristics of the invention will be convered by its field of protection. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 11/049,293, filed Feb. 3, 2005, which claims benefit priority of U.S. Provisional Application No. 60/541,949, filed Feb. 5, 2004, each of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to structures produced by techniques of nanotechnology, and methods of producing such structures. More specifically, the invention relates to such structures and devices incorporating at least one element, essentially in one-dimensional form, which is of nanometer dimensions in its width or diameter, which is produced with the aid of a catalytic particle, and which is commonly termed a “nanowhisker.”
2. Background Art
Nanotechnology covers various fields, including that of nanoengineering, which may be regarded as the practice of engineering on the nanoscale. This may result in structures ranging in size from small devices of atomic dimensions, to much larger scale structures for example, on the microscopic scale. Typically, nanostructures are devices having at least two dimensions less than about 1 μm (i.e., nanometer dimensions). Ordinarily, layered structures or stock materials having one or more layers with a thickness less than 1 μm are not considered to be nanostructures. Thus, the term nanostructures includes free-standing or isolated structures that have two dimensions less than about 1 μm, that have functions and utilities different from those of larger structures, and that are typically manufactured by methods different from conventional procedures for preparing somewhat larger, i.e., microscale, structures. Although the exact boundaries of the class of nanostructures are not defined by a particular numerical size limit, the term has come to signify such a class that is readily recognized by those skilled in the art. In many cases, an upper limit of the size of the at least two dimensions that characterize nanostructures is about 500 nm. In some technical contexts, the term “nanostructure” is construed to cover structures having at least two dimensions of about 100 nm or less. In a given context, the skilled practitioner will recognize the range of sizes intended. In this application, the term “nanostructure” is broadly intended to refer to an elongated structure having at least two transverse dimensions less than about 1 μm, as indicated above. In more preferred applications, such dimensions will be less than about 100 nm, more preferably less than about 50 nm, and even more preferably less than about 20 nm.
Nanostructures include one-dimensional nanoelements, essentially in one-dimensional form, that are of nanometer dimensions in their width or diameter, and that are commonly known as nanowhiskers, nanorods, nanowires, nanotubes, etc.
The basic process of whisker formation on substrates by the so-called VLS (vapor-liquid-solid) mechanism is well known. A particle of a catalytic material, usually gold, is placed on a substrate and heated in the presence of certain gases to form a melt. A pillar forms under the melt, and the melt rises up on top of the pillar. The result is a whisker of a desired material with the solidified particle melt positioned on top. See Wagner, Whisker Technology , Wiley, New York, 1970, and E. I Givargizov, Current Topics in Materials Science , Vol. 1, pages 79-145, North Holland Publishing Company, 1978. In early applications of this technique, the dimensions of such whiskers were in the micrometer range, but the technique has since also been applied for the formation of nanowhiskers. For example, International Patent Application Publication No. WO 01/84238 (the entirety of which is incorporated herein by reference) discloses in FIGS. 15 and 16 a method of forming nanowhiskers, wherein nanometer sized particles from an aerosol are deposited on a substrate and these particles are used as seeds to create filaments or nanowhiskers.
Although the growth of nanowhiskers catalyzed by the presence of a catalytic particle at the tip of the growing whisker has conventionally been referred to as the VLS (Vapor-Liquid-Solid process), it has come to be recognized that the catalytic particle may not have to be in the liquid state to function as an effective catalyst for whisker growth. At least some evidence suggests that material for forming the whisker can reach the particle-whisker interface and contribute to the growing whisker even if the catalytic particle is at a temperature below its melting point and presumably in the solid state. Under such conditions, the growth material, e.g., atoms that are added to the tip of the whisker as it grows, may be able to diffuse through a the body of a solid catalytic particle or may even diffuse along the surface of the solid catalytic particle to the growing tip of the whisker at the growing temperature. Persson et al., “Solid-phase diffusion mechanism for GaAs nanowires growth,” Nature Materials , Vol. 3, October 2004, pp 687-681, shows that, for semiconductor compound nanowhiskers there may occur solid-phase diffusion mechanism of a single component (Ga) of a compound (GaAs) through a catalytic particle. Evidently, the overall effect is the same, i.e., elongation of the whisker catalyzed by the catalytic particle, whatever the exact mechanism may be under particular circumstances of temperature, catalytic particle composition, intended composition of the whisker, or other conditions relevant to whisker growth. For purposes of this application, the term “VLS process,” or “VLS mechanism,” or equivalent terminology, is intended to include all such catalyzed procedures wherein nanowhisker growth is catalyzed by a particle, liquid or solid, in contact with the growing tip of the nanowhisker.
For the purposes of this specification the term “nanowhisker” is intended to mean a one-dimensional nanoelement with a width or diameter (or, generally, a cross-dimension) of nanometer size, the element preferably having been formed by the so-called VLS mechanism, as defined above. Nanowhiskers are also referred to in the art as “nanowires” or, in context, simply as “whiskers” or “wires.”
Freestanding nanowhiskers have drawn increasing attention for their potential use in applications in electronics and photonics.
As already shown in the early work of Wagner, referenced above, the preferential growth direction of such nanowhiskers is <111>. One drawback of <111> oriented nanowhiskers is the high density of stacking faults that commonly form perpendicular to the growth direction. These defects are expected to affect the physical properties of the nanowhiskers. Another drawback with this preferential growth direction is its non-compatibility with the (001) crystal face of the main surface of substrates commonly used in industrial applications. That is, the preferential growth direction is oblique rather than normal to the substrate main surface, the normal direction being <001>. For example, with III-V compounds, the commonly commercially available substrates have an (001) crystal face as the main surface. In contrast, nanowhiskers of III-V compounds preferentially grow in a <111>B direction from a (111)B crystal plane.
Hiruma et al., J. Appl. Phys., 77(2), 15 Jan. 1995, pages 447-462, reported the growth on InAs nanowhiskers on GaAs substrates having various surfaces including, in particular, the (001) surface. The InAs nanowires invariably grew in the <111> direction, resulting, for example, in pairs of wires ([1-11] and [-111]) tilted with an angle of 35° towards the (001) surface.
Other growth directions for nanowhiskers have been observed to occur sporadically during whisker growth. For instance, Wu et al, “Growth, branching, and kinking of molecular beam epitaxial <110> GaAs nanowires,” Applied Physics Letters. 20 Oct. 2003, Vol. 83, No. 16, pp 3368-3370, disclosed an <011> direction for GaAs nanowhiskers grown on GaAs (001) by molecular beam epitaxy (MBE).
Björk et al, “One-Dimensional Heterostructures In Semiconductor Nanowhiskers,” Applied Physics Letters , Vol. 80, No. 6, 11 Feb. 2002, pages 1058-1060, described an <001> segment of an InAs/InP heterostructured nanowhisker grown from a (111)B GaAs surface in chemical beam epitaxy (CBE), the segment having deviated from the initial <111>B growth direction of the nanowhisker. More particularly, it had been observed that whereas most nanowhiskers grew in the <111>B direction, there were sporadically formed nanowhiskers in the form of a “hockey-stick” that initially grew in the <111>B direction, but “kinked” to the <001> direction. The nanowhisker disclosed had a base region of InAs and grew in the <001> direction as a result of the compressive strain at the InP/InAs interface. Growth of a nanowhisker in the <001> direction dramatically reduces the formation of defects, such as stacking faults.
In International Patent Application Publication No. WO 2004/004927 (the entirety of which is incorporated herein by reference), there is disclosed in FIG. 24(b) a technique for controlling the growth direction of whiskers wherein, by applying strain to the whisker during formation, by change of growth conditions, the direction of growth of the whisker can be changed to the <100> direction from the usual <111> direction. Alternatively, a short bandgap segment of a wide bandgap material may be grown at the base of the nanowhisker.
Still further improvements in the control of the growth direction of nanowhiskers are desirable. For example, a method that would provide for an initial whisker growth direction normal to an incompatible substrate surface—that is, where the preferential growth direction of the whisker is oblique to the surface—would be highly desirable, as would structures produced by such method. Such a method would allow for the growth of whiskers that are normal to the surface over their entire length (or, more generally, at least the initial portion of their length) as opposed to the kinked nanowhiskers having an initial growth direction oblique to the surface as previously observed.
SUMMARY OF THE INVENTION
The present invention relates to directionally controlled growth of nanowhiskers and to structures including such nanowhiskers, and provides, among other things, methods and structures having the highly desirable characteristics just described. The invention thus provides methods and structures in which a nanowhisker has at least a base portion grown in a non-preferential growth direction from a substrate surface.
DISCLOSURE OF THE INVENTION
The invention, from one perspective, recognizes that nanowhiskers of particular semiconductor materials have preferential directions for growth, and that commonly available substrates of particular semiconductor materials have particular crystal facets defining a major surface that does not correspond to a preferential growth direction. The present invention therefore provides a mechanism for growth of nanowhiskers that will permit growth of nanowhiskers in a non-preferential growth direction from a substrate major surface defined by a crystal facet that does not correspond to a preferential growth direction.
The invention also provides a nano-engineered structure that comprises a nanowhisker upstanding from (or at least having an initial or base portion upstanding from) a substrate major surface in a non-preferential growth direction, wherein a crystal facet defining the surface corresponds to the non-preferential direction of growth of the nanowhisker. The growth direction of the nanowhisker is preferably maintained over its entire length. However, it is within the broader scope of the invention that the growth direction can be changed from the initial, non-preferential growth direction by changing growth conditions (e.g., constituent materials) of the whisker after growth of the whisker base portion.
More generally, the invention provides nanostructures incorporating nanowhiskers grown on substrates, having improved structural form.
For the purposes of this specification, it will be understood that where a surface or crystal facet is defined by Miller indices (hkl), where h, k and l are numerical values, then this “corresponds” to a nanowhisker growth direction <hkl>.
The present invention, from another perspective, recognizes that where it is desired deliberately to grow a nanowhisker from a substrate surface in a non-preferential growth direction, nucleation conditions at the onset of growth can be regulated such that there is not created at an interface between a catalytic particle and the substrate a condition that would cause growth of the nanowhisker in a preferential growth direction.
Thus, in accordance with another of its aspects, the invention provides a method of growing nanowhiskers on a substrate surface providing a predetermined crystal plane, the method comprising providing at least one catalytic particle on the substrate surface, and growing a nanowhisker from each said catalytic particle in a predetermined growth direction that is a non-preferential growth direction for the nanowhisker, with nucleation conditions at the onset of growth being regulated to control the interface between each said catalytic particle and the substrate such that said crystal plane is maintained as said substrate surface at the interface so as to define and stabilize said predetermined growth direction. The nanowhisker can be of the same material or of a different material from that of the substrate.
In accordance with the present invention, the nanowhisker growth direction can be defined and stabilized by controlling the surface conditions at the onset of the nucleation event. This nucleation can be strongly affected by pre-treatment of the catalytic particle at the substrate surface. Conventionally, an annealing step at high temperature is performed subsequent to providing the catalytic particles on the substrate surface and prior to initiation of nanowhisker growth. In such an annealing step, substrate material is consumed by or dissolved into the catalytic particles, and this creates depressions or recesses in the substrate surface in which the catalytic particles sit. Such depressions may expose crystal facets such as (111) that may bring about nanowhisker growth perpendicular to such facets in a preferential direction such as <111>. Thus, in practice of the present invention, such an annealing step is preferably omitted. More generally, the nucleation stage of initial nanowhisker growth preferably comprises absorbing constituent materials from the gaseous phase to create supersaturation conditions within the catalytic particle; substrate material does not contribute to a significant extent.
When nucleation conditions are initiated, it is preferred to maintain temperature as low as possible, consistent with ensuring proper nucleation and growth. Further, it has been found that the catalytic particle, when heated under such conditions, may perform an “ironing” effect on the underlying substrate surface to “iron-out” irregularities, atomic steps, etc., and this further contributes to maintaining a well-defined surface. The surface may amount to an atomically flat surface, with no atomic steps, etc., so that a nanowhisker has no other possibility than to grow in the desired non-preferential direction. However, perfect atomic flatness may not be necessary in order to force growth in the desired direction.
Further, the catalytic particle, while usually of a non-reactive material such as Au, may be formed of, or include, a constituent element (e.g., a group III material such as In) of the nanowhisker. Nucleation and supersaturation conditions may thus be achieved more quickly, with a reduced amount of the constituent material being absorbed into the catalytic particle from its surroundings.
In a further aspect, the invention provides a structure comprising a substrate having a surface providing an (001) crystal plane, and at least one nanowhisker extending, at least initially, from the surface in an <001> direction relative to the surface, wherein the <001> direction corresponds to a non-preferential direction of growth for the nanowhisker, in that one or more other directions are more conducive to growth.
In a more general aspect, the invention provides a structure comprising a substrate having a major surface defined by a predetermined crystal plane, and at least one nanowhisker extending, at least initially, from the surface in a direction corresponding to the crystal plane, wherein the direction of the nanowhisker is a non-preferential direction of growth for the nanowhisker, in that one or more other directions are more conducive to growth.
It has been found that the (001) surface of III-V materials is particularly conducive to bulk epitaxial growth, when exposed to appropriate materials in gaseous form. This may compete with, inhibit or obstruct nanowhisker growth.
In accordance with a further aspect of the invention, a method of growing nanowhiskers on a substrate surface comprises disposing at least one catalytic particle on the substrate surface, the substrate surface providing a predetermined crystal plane, and growing a nanowhisker from each said catalytic particle in a predetermined direction from the surface that does not correspond to a preferential direction of growth for the nanowhisker, and wherein prior to establishment of growth conditions, a mask of passivating material is formed on the substrate surface to inhibit bulk growth of material used to form the nanowhisker.
In one preferred implementation, the invention provides a method of growing nanowhiskers on an (001) surface of a substrate of III-V semiconductor material, wherein at least one catalytic particle is disposed on the (001) substrate surface, and growth conditions are established wherein heat is applied, and constituent materials are introduced in gaseous form, from which to grow a nanowhisker from each said catalytic particle in an <001> direction relative to the surface, and wherein prior to establishment of growth conditions, a mask of passivating material is formed on the substrate surface to inhibit bulk growth.
In a further aspect, the invention provides a structure comprising a substrate having a surface defined by a predetermined crystal facet, and at least one nanowhisker extending from said surface in a direction corresponding to said crystal facet, but not corresponding to a preferential direction of growth for the nanowhisker, and a layer of passivating material disposed on the substrate surface.
In one preferred form, the structure comprises a substrate of III-V semiconductor material having an (001) surface, and at least one nanowhisker extending from said surface in an <001> direction relative to the surface, and a layer of passivating material disposed on the substrate surface.
The mask of passivating material may be silicon oxide or silicon nitride, as described in copending U.S. patent application Ser. No. 10/751,944, filed Jan. 7, 2004 (the entirety of which is incorporated herein by reference). Each catalytic particle may be disposed in a respective aperture within the mask. Alternatively, and as preferred, a layer of carbon containing material can be employed that is deposited over the substrate and the catalytic particles. A particularly preferred material is Lysine (an amino acid). When heated, the material decomposes to leave a thin layer, which may be as thin as a monolayer, of a material that contains carbon and serves to inhibit bulk growth on the substrate. Although the layer coats in addition the catalytic particle, it is so thin that it does not disturb or inhibit nanowhisker growth.
It is preferred to use, as a method of positioning the catalytic particle on the substrate surface, deposition of the particle from an aerosol. A method as described in International Patent Application Publication No. WO 01/84238 (the entirety of which is incorporated herein by reference) may be employed. In the situation where it is desired to use a lithographic process for positioning catalytic particles such as gold on the substrate, it is appropriate to ensure that none of the process steps, such as etching a mask to define positions for the catalytic particles, creates undesirable depressions.
As regards the material of the catalytic particle, this may comprise a non-reactive material such as Au. Alternatively, the Au may be alloyed with a group III material, for example, that forms part of the nanowhisker compound. Alternatively, the particle may be heterogeneous—for example, with one region of Au and another region of group III material. Alternatively, the catalytic particle may be formed wholly of a group III material, such as In.
As regards the material of the nanowhiskers, this need not be the same as that of the substrate and may be of any desired material. When forming semiconductor nanowhiskers on a semiconductor substrate, the material of the whiskers can be of the same semiconductor group as that of the substrate material, or of a different semiconductor group. A specific implementation described hereinafter, and having achieved excellent results, involves InP nanowhiskers grown in an <001> direction on an (001) InP substrate surface.
In addition to III-V materials, substrates of groups IV and II-VI semiconductor materials, and other substrate materials, may be used for nanowhisker growth. Substrates of III-V materials are commonly provided in commerce with (001) surfaces; substrates with (111) surfaces are much more expensive. While specific implementation of the invention is described hereinafter with reference to InP, the invention may also be practiced with GaP and InAs substrates, for example. Substrates of material that contain Ga may have thicker and more resistant oxide formations that should preferably be removed prior to nucleation, without forming a depression in the substrate surface.
Among group IV semiconductor substrate materials, Si is widely used as a substrate material in the manufacture of electronic components. Stable silicon surfaces include (001), (111), and (113). Most electronic components are fabricated on (001) surfaces. Heretofore, nanowhiskers have been grown in the preferential (and oblique) <111> direction from (001) surfaces. In accordance with the techniques of the present invention, however, nanowhiskers can be grown in a direction normal to such surfaces not corresponding to a preferential growth direction—for example, in an <001> direction from an (001) surface.
The present invention is, in principle, applicable to any of the materials that may be used in the manufacture of nanowhiskers and substrates therefor. Such materials are commonly semiconductors formed of Group II through Group VI elements. Such elements include, without limitation, the following:
Group II: Be, Mg, Ca; Zn, Cd, Hg;
Group III: B, Al, Ga, In, TI;
Group IV: C, Si, Ge, Sn, Pb;
Group V: N, P, As, Sb;
Group VI: O, S, Se, Te.
Semiconductor compounds are commonly formed of two elements to make III-V compounds or II-VI compounds. However, ternary or quaternary compounds are also employed involving, e.g., two elements from Group II or from Group III. Stoichiometric or non-stoichiometric mixtures of elements can be employed.
III-V materials and II-VI materials include, without limitation, the following:
AlN, GaN, SiC, BP, InN, GaP, AlP, AlAs, GaAs, InP, PbS, PbSe, InAs, ZnSe, ZnTe, CdS, CdSe, AlSb, GaSb, SnTe, InSb, HgTe, CdTe, ZnTe, ZnO.
There are many other semiconductor materials to which the invention is applicable: see, for example, “Handbook of Chemistry and Physics”—CRC—Properties of Semiconductors—for a more complete treatment.
In accordance with the invention, a semiconductor substrate may be selected from one of the above group IV, III-V or II-VI materials, and the nanowhiskers may be selected from the same or another of the group IV, III-V or II-VI materials.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention will now be described with reference to the accompanying drawings, wherein:
FIGS. 1( a ) to 1 ( d ) are SEM-images of InP nanowhiskers on a substrate of IP (001), in accordance with the invention: (a) top-view, (b) enlarged top-view, (c) view on a substrate tilted by 30°, (d) magnification of a single whisker after a clockwise rotation of the substrate by 40°.
FIGS. 2( a ) and 2 ( b ) are schematic diagrams for explaining the invention in terms of different growth directions by different start (nucleation) conditions.
FIGS. 3( a ) to 3 ( e ) are TEM-images of InP nanowhiskers to illustrate comparative characteristics of nanowhiskers grown in a non-preferential <001> direction in accordance with the invention relative to nanowhiskers grown in a preferential <111>B direction.
FIG. 4( a ) shows photoluminescence spectra from an <001> nanowhisker in accordance with the invention (thick line) and a typical <111>B whisker (thin line), and FIG. 4( b ) is an SEM image of the <001> whisker having the photoluminescence spectrum in FIG. 4( a ).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, it is has been found that growth of a nanowhisker in a non-preferential direction (e.g., in an <001> direction from an (001) crystal plane) is, once established, stable. The present invention more particularly recognizes the possibility to define and to stabilize the growth direction by controlling conditions at the onset of the nucleation event.
The following discussion describes an exemplary application of the invention to [001] InP nanowhiskers grown by metal-organic vapor phase epitaxy directly on (001) InP substrates. The nanowhiskers were characterized by scanning electron microscopy and transmission electron microscopy and found to have structural characteristics substantially superior to those of comparative whiskers grown in the preferential <111>B direction, as will be discussed in detail below.
The InP nanowhiskers were grown using low-pressure metal-organic vapor phase epitaxy (MOVPE). Aerosol-produced, 50 nm Au-particles were deposited on (001) InP substrates, which were then placed within a horizontal reactor cell on an RF-heated graphite susceptor. A hydrogen carrier gas flow of 6 l/min at a pressure of 100 mBar (10 kPa) was used. A constant phosphine flow at a molar fraction of 1.5×10 −2 was supplied to the reactor cell and the samples were heated up to 420° C. over 5 minutes. After this temperature ramp step, growth of nanowhiskers was immediately commenced by introducing trimethylindium (TMI) into the reactor cell. The TMI molar fraction was 3×10 −6 , and the typical growth time was 8 minutes. It should be noted that this method of producing whiskers differs from the often-used procedure of whisker growth, where Au particles are annealed at higher temperature prior to whisker growth in order to de-oxidize the surface and alloy the Au catalyst with the semiconductor material. In addition, in order to improve the growth of [001] nanowhiskers in relation to competing bulk growth at the (001) surface, the substrate with the deposited Au particles was dipped into a solution of poly-L-Lysine before inserting it into the growth chamber. L-Lysine (2,6 diaminocaproic acid) is known to be an adhesion-active substance with low vapor pressure. The monohydrate melts under decomposition between 212-214° C., leaving a thin passivation layer at the surface. This layer prevents InP-growth on the bare (001) InP surface.
Sample characterization was carried out using a JSM 6400 F field emission scanning electron microscope (SEM), operated at 15 kV. FIGS. 1( a ) to 1 ( d ) show SEM-images of [001] InP nanowhiskers grown by the procedures described above. FIG. 1( a ) is a top view. FIG. 1( b ) is an enlarged top view. FIG. 1( c ) is view on a substrate tilted by 30°, and FIG. 1( d ) shows magnification of a single whisker after a clockwise rotation of the substrate by 40°. In FIG. 1( b ), a rectangular whisker shape formed by stepped {110} side-facets of the [001] oriented whiskers is clearly evident.
A most remarkable effect of the whisker growth in [001] is the high crystalline perfection observed. FIGS. 3( a ) to 3 ( e ) show high-resolution transmission electron microscopy (TEM) images of InP wires grown in [001] and <111>B in comparison. The [001] wires appear to be defect-free, whereas <111>B grown whiskers contain a high concentration of stacking faults. The energetic differences for hexagonal or cubic stacking sequences in <111>B are small, and the stacking faults, as planar defects vertical to the growth direction, can freely end at the nanowhisker side facets. The formation of similar defects during growth in [001] would need to overcome an activation barrier for the creation of Frank partial dislocations. FIG. 3( a ) is a side view showing a defect-free [001]-grown nanowhisker. FIG. 3( b ) is an enlargement of the boxed area in FIG. 3( a ), showing the atomic lattice of the defect-free zincblende structure in a [110] projection. FIG. 3( c ) is a Fourier transform of the [110] projection. FIG. 3( d ) is a side view showing a conventionally grown <111>B-directed nanowhisker with stacking faults all along the wire. FIG. 3( e ) is a close-up of the nanowhisker of FIG. 3( d ), showing mirror plane stacking faults resulting in wurtzite-structure segments.
The TEM images of FIGS. 3( a ) to 3 ( e ) were taken from nanowhiskers broken off from the substrate by touching a TEM grid to the nanowhisker substrate.
The higher materials perfection for nanowhiskers grown in [001] was also evident in photoluminescence studies. For photoluminescence (PL) studies, nanowhiskers were transferred to a thermally oxidized Si wafer on which a gold pattern was created to facilitate localization and identification of the whiskers studied by PL. The measurements were performed at liquid-He temperatures. A frequency-doubled Nd-YAG laser emitting at 532 nm was used for excitation. The luminescence was collected through an optical microscope, dispersed through a spectrometer, and detected by a liquid-N 2 cooled CCD.
Photoluminescence measurements of single [001] InP nanowhiskers grown in accordance with the invention exhibited a narrow and intense emission peak at approximately 1.4 eV, whereas <111>B conventionally grown reference whiskers showed additional broad luminescence peaks at lower energy. FIG. 4( a ) shows photoluminescence spectra from an <001> nanowhisker of the invention, with strong bandgap-related luminescence associated with the whisker (thick line) and a typical <111>B whisker with weaker luminescence and an additional broad peak at lower energies (thin line; small peaks superimposed on top of the broad main feature are artifacts resulting from interference within the CCD). FIG. 4( b ) shows an SEM image of the <001> whisker, showing the strong PL in FIG. 4( a ).
The differences between the situation with and without annealing may be explained by the schematics in FIGS. 2( a ) and 2 ( b ). FIG. 2 ( a ) shows growth from an Au-droplet at the (001) surface after annealing. InP will be locally dissolved to form an Au/In alloy, resulting in the formation of a pit. Two side facets within the pit are of {111}B-character. At high temperature (>500° C.), InP will be locally dissolved in a reaction with the Au. Typical Au/semiconductor interfaces, which develop under such conditions within the pit, are the low-energy facets {111}B and {011}, rather than the (001) facet which defines the substrate major surface. Nucleation on such low-energy facets could be the starting point for the commonly observed whisker growth in [1-11] and [-111], as well as the more seldom observed <011> direction reported for GaAs-MBE.
FIG. 2( b ) shows growth, in accordance with the invention, from an Au-droplet without annealing. The Au/In-alloy forms by reaction of the Au with TMI, such that the (001) surface underneath the Au-droplet remains essentially intact. Without annealing at higher temperature, the reaction between InP and Au will be suppressed. In and P, dissolved within the Au-droplet, will be mostly from the supply of TMI and PH 3 from the vapor phase, and not at the cost of the substrate material. Upon reaching a critical supersaturation, nucleation starts at the InP (001)/Au interface, and, consequently, wire growth can be controlled to occur in the [001] direction. In all samples, areas were found where [001] wires were dominant, but also areas with dominantly <111>B wires. Since slightly misoriented substrates (0.2°) were used, this different behavior may be due to lateral differences in the step structure at the (001) substrate surface.
It will thus be appreciated that the invention can achieve, among other advantages, (1) nano-wires which are highly perfect zincblende crystals that are free of stacking faults, exhibiting intense single-wire luminescence, and (2) the capability of vertical growth on the industrially viable (001) substrate orientation. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 12/399,331 filed Mar. 6, 2009, which claims the benefit of provisional U.S. Patent Application No. 61/034,312, filed Mar. 6, 2008, which is incorporated herein in its entirety.
FIELD OF THE INVENTION
The present invention relates to communication cables, and more particularly to methods and apparatus to enhance the attenuation of crosstalk associated with such cables.
BACKGROUND OF THE INVENTION
As networks become more complex and have a need for higher bandwidth cabling, attenuation of cable-to-cable crosstalk (or “alien crosstalk”) becomes increasingly important to provide a robust and reliable communication system. Alien crosstalk is primarily coupled electromagnetic noise that can occur in a disturbed cable arising from signal-carrying cables that run near the disturbed cable. Additionally, crosstalk can occur between twisted pairs within a particular cable, which can additionally degrade a communication system's reliability.
SUMMARY OF THE INVENTION
In some embodiments, the present invention relates to the use of multiple layers of material having conductive segments as a method of enhancing the attenuation of alien crosstalk. In one embodiment, the present invention comprises a double-layered metal patterned film (or barrier tape) that is wrapped around the wire pairs of a high performance 10 Gb/s (gigabit/second) unshielded twisted pair (UTP) cable. In general, the present invention can be used in communication cable of higher or lower frequencies, such as (TIA/EIA standards) Category 5e, Category 6, Category 6A, Category 7, and copper cabling used for even higher frequency or bit rate applications, such as, 40 Gb/s and 100 Gb/s. The conductive segments in the layers are positioned so that gaps in one layer are substantially overlain by conductive segments of a neighboring layer. The multiple layers reduce crosstalk while gaps between the conductive segments reduce the emission of electromagnetic energy from the conductive material and also reduce the susceptibility of the conductive material to radiated electromagnetic energy. The present invention solves deficiencies in the prior art of UTP cable to reduce cable-to-cable crosstalk, or other types of crosstalk. Embodiments of the present invention may be applied to other types of cable in addition to UTP cable.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of facilitating an understanding of the inventions, the accompanying drawings and description illustrate embodiments thereof, from which the inventions, structure, construction and operation, and many related advantages may be readily understood and appreciated.
FIG. 1 is a schematic view of an embodiment of a communication system including multiple communication cables according to the present invention;
FIG. 2 is a cross-sectional view of one of the communication cables of FIG. 1 ;
FIG. 3 is a fragmentary plan view of an embodiment of a barrier tape according to the present invention and used in the cables of FIGS. 1 and 2 ;
FIG. 4 is a cross-sectional view of the barrier tape of FIG. 3 , taken along section 4 - 4 in FIG. 3 ;
FIG. 5 is a longitudinal cross-sectional view of the parasitic capacitive modeling of two prior art cables;
FIG. 6 is a longitudinal cross-sectional view of the parasitic capacitive modeling of two cables according to an embodiment of the present invention;
FIG. 7 is a longitudinal cross-sectional view of a parasitic inductive modeling of two prior art cables;
FIG. 8 is a longitudinal cross-sectional view of a parasitic inductive modeling of two cables according to an embodiment of the present invention
FIG. 9 is a perspective view of an embodiment of the cable of FIG. 1 , illustrating the spiral nature of the barrier tape installed within the cable;
FIG. 10 is a fragmentary plan view of an embodiment of a barrier tape according to the present invention in the form of a triple layer patterned discontinuous conductive material on an insulative substrate material;
FIG. 11 is a fragmentary plan view of another embodiment of a barrier tape according to the present invention;
FIG. 12 is a cross-sectional view of the barrier tape of FIG. 11 taken along the line 12 - 12 of FIG. 11 ;
FIG. 13 is a cross-sectional view of a cable according to one embodiment of the present invention having an alternative twisted-pair divider;
FIG. 14 is a cross-sectional view of a cable according to another embodiment of the present invention having an alternative twisted-pair divider;
FIG. 15 is a cross-sectional view of a cable incorporating an embossed film as an insulating layer;
FIG. 16 is a cross-sectional view of a cable incorporating a embossed films as twisted pair separators and as an insulating layer; and
FIG. 17 is a plan view of an embossed film.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring now to the drawings, and more particularly to FIG. 1 , there is shown a communication system 20 , which includes at least one communication cable 22 , connected to equipment 24 . Equipment 24 is illustrated as a patch panel in FIG. 1 , but the equipment can be passive equipment or active equipment. Examples of passive equipment can be, but are not limited to, modular patch panels, punch-down patch panels, coupler patch panels, wall jacks, etc. Examples of active equipment can be, but are not limited to, Ethernet switches, routers, servers, physical layer management systems, and power-over-Ethernet equipment as can be found in data centers/telecommunications rooms; security devices (cameras and other sensors, etc.) and door access equipment; and telephones, computers, fax machines, printers and other peripherals as can be found in workstation areas. Communication system 20 can further include cabinets, racks, cable management and overhead routing systems, for example.
Communication cable 22 can be in the form of an unshielded twisted pair (UTP) cable, and more particularly a Category 6A cable which can operate at 10 Gb/s, as is shown more particularly in FIG. 2 , and which is described in more detail below. However, the present invention can be applied to and/or implemented in a variety of communications cables, as have already been described, as well as other types of cables. Cables 22 can be terminated directly into equipment 24 , or alternatively, can be terminated in a variety of plugs 25 or jack modules 27 such as RJ45 type, jack module cassettes, Infiniband connectors, RJ21, and many other connector types, or combinations thereof. Further, cables 22 can be processed into looms, or bundles, of cables, and additionally can be processed into preterminated looms.
Communication cable 22 can be used in a variety of structured cabling applications including patch cords, backbone cabling, and horizontal cabling, although the present invention is not limited to such applications. In general, the present invention can be used in military, industrial, telecommunications, computer, data communications, and other cabling applications.
Referring more particularly to FIG. 2 , there is shown a transverse cross-section of cable 22 . Cable 22 includes an inner core 23 of four twisted conductive wire pairs 26 that are typically separated with a crossweb 28 . An inner insulating layer 30 (e.g., a plastic insulating tape or an extruded insulating layer, for example a 10 mil thick inner insulating jacket material) surrounds the conductive wire pairs 26 and cross web 28 . A wrapping of barrier tape 32 surrounds the inner insulating layer 30 . Barrier tape 32 can be helically wound around the insulating layer 30 . Cable 22 also can include an outer insulating jacket 33 . The barrier tape 32 is shown in a condensed version for simplicity in FIG. 2 , illustrating only an insulating substrate 42 and conductive segments 34 and 38 . Referring also to FIGS. 3 and 4 , and as is discussed in more detail below, barrier tape 32 includes a first barrier layer 35 (shown in FIG. 2 as a inner barrier layer) comprising conductive segments 34 separated by gaps 36 ; a second barrier layer 37 (shown in FIG. 2 as an outer barrier layer) comprising conductive segments 38 separated by gaps 40 in the conductive material of segments 38 ; and an insulating substrate 42 separating conductive segments 34 and gaps 36 of the first conductive layer from conductive segments 38 and gaps 40 of the second conductive layer. The first and second barrier layers, and more particularly conductive segments 34 and conductive segments 38 , are staggered within the cable so that gaps 40 of the outer barrier layer align with the conductive segments 34 of the inner conductive layer. Barrier tape 32 can be helically or spirally wound around the inner insulating layer 30 . Alternatively, the barrier tape can be applied around the insulative layer in a non-helical way (e.g., cigarette or longitudinal style).
Outer insulating jacket 33 , can be 15 mil thick (however, other thicknesses are possible). The overall diameter of cable 22 can be under 300 mils, for example; however, other thicknesses are possible.
FIG. 3 is a plan view of barrier tape 32 illustrating the patterned conductive segments on an insulative substrate where two barrier layers 35 and 37 of discontinuous conductive material are used. The conductive segments 34 and 38 are arranged as a mosaic in a series of plane figures along both the longitudinal and transverse direction of an underlying substrate 42 . As described, the use of multiple barrier layers of patterned conductive segments facilitates enhanced attenuation of alien crosstalk, by effectively reducing coupling by a cable 22 to an adjacent cable, and by providing a barrier to coupling from other cables. The discontinuous nature of the conductive segments 34 and 38 reduces or eliminates radiation from the barrier layers 35 and 37 . In the embodiment shown, a double-layered gridlike metal pattern is incorporated in barrier tape 32 , which spirally wraps around the twisted wire pairs 26 of the exemplary high performance 10 Gb/s cable. The pattern may be chosen such that conductive segments of a barrier layer overlap gaps 36 , 40 from the neighboring barrier layer. In FIGS. 3 and 4 , for example, both the top 35 and bottom 37 barrier layers have conductive segments that are arranged in a series of squares (with rounded corners) approximately 330 mil×330 mil with a 60 mil gap size 44 between squares. According to one embodiment, the rounded corners are provided with a radius of approximately 1/32″.
Referring to the upper barrier layer 35 , the performance of any single layer of conductive material is dependent on the gap size 44 of the discontinuous pattern and the longitudinal length 46 of the discontinuous segments and can also be at least somewhat dependent on the transverse widths 48 of the conductive segments. In general, the smaller the gap size 44 and longer the longitudinal length 46 , the better the cable-to-cable crosstalk attenuation will be. However, if the longitudinal pattern length 46 is too long, the layers of discontinuous conductive material will radiate and be susceptible to electromagnetic energy in the frequency range of relevance. One solution is to design the longitudinal pattern length 46 so it is slightly greater than the average pair lay of the twisted conductive wire pairs within the surrounded cable but smaller than one quarter of the wavelength of the highest frequency signal transmitted over the wire pairs. The pair lay is equal to the length of one complete twist of a twisted wire pair.
Typical twist lengths (i.e., pair lays) for high-performance cable (e.g., 10 Gb/s) are in the range of 0.8 cm to 1.3 cm. Hence the conductive segment lengths are typically within the range of from approximately 1.3 cm to approximately 10 cm for cables adapted for use at a frequency of 500 MHz. At higher or lower frequencies, the lengths will vary lower or higher, respectively.
Further, for a signal having a frequency of 500 MHz, the wavelength will be approximately 40 cm when the velocity of propagation is 20 cm/ns. At this wavelength, the lengths of the conductive segments of the barrier layers should be less than 10 cm (i.e., one quarter of a wavelength) to prevent the conductive segments from radiating electromagnetic energy.
It is also desirable that the transverse widths 48 of the conductive segments “cover” the twisted wire pairs as they twist in the cable core. In other words, it is desirable for the transverse widths 48 of the conductive segments to be wide enough to overlie a twisted pair in a radial direction outwardly from the center of the cable. Generally, the wider the transverse widths 48 , the better the cable-to-cable crosstalk attenuation is. It is further desirable for the barrier tape 32 to be helically wrapped around the cable core at approximately the same rate as the twist rate of the cable's core. For high-performance cable (e.g., 10 Gb/s), typical cable strand lays (i.e., the twist rate of the cable's core) are in the range of from approximately 6 cm to approximately 12 cm. It is preferred that barrier tapes according to the present invention are wrapped at the same rate as the cable strand lay (that is, one complete wrap in the range of from approximately 6 cm to approximately 12 cm). However, the present invention is not limited to this range of wrap lengths, and longer or shorter wrap lengths may be used.
A high-performing application of a barrier tape of discontinuous conductive segments is to use one or more conductive barrier layers to increase the cable-to-cable crosstalk attenuation. For barriers of multiple layers, barrier layers are separated by a substrate so that the layers are not in direct electrical contact with one another. Although two barrier layers 35 and 37 are illustrated, the present invention can include a single barrier layer, or three or more barrier layers. (See FIG. 10 for example.)
FIG. 4 illustrates a cross-sectional view of barrier tape 32 in more detail as employed with two barrier layers 35 and 37 . Each barrier layer includes a substrate 50 and conductive segments 34 or 38 . The substrate 50 is an insulative material and can be approximately 0.7 mils thick, for example. The layer of conductive segments contains plane figures, for example squares with rounded corners, of aluminum having a thickness of approximately 0.35 mils. According to other embodiments of the present invention, the conductive segments may be made of different shapes such as regular or irregular polygons, other irregular shapes, curved closed shapes, isolated regions formed by conductive material cracks, and/or combinations of the above. Other conductive materials, such as copper, gold, or nickel may be used for the conductive segments. Semiconductive materials may be used in those areas as well. Examples of the material of the insulative substrate include polyester, polypropylene, polyethylene, polyimide, and other materials.
The conductive segments 34 and 38 are attached to a common insulative substrate 42 via layers of spray glue 52 . The layers of spray glue 52 can be 0.5 mils thick and the common layer of insulative substrate 42 can be 1.5 mil thick, for example. Given the illustrated example thicknesses for the layers, the overall thickness of the barrier tape 32 of FIG. 4 is approximately 4.6 mils. It is to be understood that different material thicknesses may be employed for the different layers. According to some embodiments, it is desirable to keep the distance between the two layers of conductive segments 34 and 38 small so as to reduce capacitance between those layers.
When using multiple layers of discontinuous conductive material as barrier material the gap coverage between layers assists in decreasing cable-to-cable crosstalk. This may be best understood by examining the capacitive and conductive coupling between cables.
FIG. 5 illustrates a model of parasitic capacitive coupling of two prior art cables 401 and 402 . Here, the two cables 401 and 402 employ insulating jackets 404 as a method of attenuating cable-to-cable crosstalk between the two twisted pairs of wire 403 of standard 10 G b/s Ethernet twist length 54 (pair lay). The resultant parasitic capacitive coupling, as illustrated by modeled capacitors 405 - 408 , creates significant cable-to-cable crosstalk. Although capacitors 405 - 408 are shown as lumped capacitive elements for the purpose of the FIG. 5 model, they are in fact a distributed capacitance.
In contrast, FIG. 6 illustrates the parasitic capacitive coupling of two cables 22 a and 22 b using the barrier technique of the present invention. Though the overall effect results from a distributed capacitance, lumped element capacitor models are shown for the purpose of illustrating the distributed parasitic capacitive coupling. First and second twisted wires 101 and 102 of the twisted pair 26 a carry a differential signal, and can be modeled as having opposite polarities. The “positive” polarity signal carried by the first wire 101 and the “negative” polarity signal carried by the second wire 102 couple approximately equally to the conductive segment 34 a. This coupling is modeled by the capacitors 504 and 505 . As a result, very little net charge is capacitively coupled from the twisted pair 26 onto the conductive segment 34 a, resulting in a negligible potential. What little charge is coupled onto the conductive segment 34 a is further distributed by coupling onto the conductive segments 38 a and 38 b in the outer barrier layer of the cable 22 a via modeled capacitors 506 and 507 . Because the conductive segments 38 a and 38 b are also capacitively coupled with additional inner conductive segments 34 b and 34 c, the amount of capacitive coupling is further mitigated due to cancellation effects resulting from the opposite polarities of the twisted wires 101 and 102 . Similar cancellation effects carry through the additional modeled capacitors 508 - 513 , so that the overall capacitive coupling between the twisted pair 26 a of the first cable 22 a and the twisted pair 26 b of the second cable 22 b is substantially decreased as compared to a prior art system. The spacing of the gaps 36 and 40 in the two barrier layers of a barrier tape greatly reduces the opportunity for direct cable-to-cable capacitive coupling.
Turning to inductive modeling, FIG. 7 illustrates the parasitic distributed inductive modeling of two prior art cables. In FIGS. 7 and 8 , currents in the conductors produce magnetic fields and the distributed inductance of the conductors results in inductive coupling shown by the arrows. For purposes of illustration, specific regions of the magnetic fields are indicated by arrows, but the magnetic fields are actually distributed throughout the illustrated areas. Here, both cables 601 and 602 employ only insulating jackets 604 as a method of attenuating cable-to-cable crosstalk between the two twisted pairs of wire 605 of standard 10 Gb/s Ethernet twist length 54 (pair lay). The resultant parasitic inductive coupling modeled at 606 - 609 creates significant cable-to-cable crosstalk.
FIG. 8 illustrates inductive modeling of two cables using the barrier techniques as proposed by the present invention. The two twisted wires of cables 22 a and 22 b respectively contain twisted pairs 26 a and 26 b and same standard 10 Gb/s Ethernet twist length 56 (pair lay), as the prior art model. However, the two cables 22 a and 22 b are protected with barrier tape 32 . The barrier layers 35 and 37 contain respective gaps 36 and 40 in the conductive material to prevent the conductive material segments 34 and 38 from radiating. The conductive segments are staggered within the cable so that most gaps in the conductive material are aligned conductive segments of the adjacent layer.
Magnetic fields are induced in the first cable 22 a by the twisted wire pair 26 a. However, as the magnetic fields pass through the inner barrier layer of the barrier tape 32 , they create eddy currents in the conductive segments, reducing the extent of magnetic coupling 710 and 711 , and reducing cable-to-cable crosstalk. However, the need for gaps 36 and 40 in the barrier layers 35 and 37 results in some portions of the magnetic fields passing near a boundary or gap. Eddy currents are not as strongly induced near a boundary or gap, resulting in less reduction of the passing magnetic field in these regions.
One solution again is to use multiple barrier layers 35 and 37 so that a gap from one layer is covered by conductive material from the adjacent layer. The second cable 22 b illustrates an outer barrier layer (particularly conductive segment 38 ) covering a gap 36 in the inner conductive layer 35 . As discussed above, the magnetic fields passing through the conductive layer 35 and 37 do not lose much energy because eddy currents are not as strongly induced near boundaries or gaps 36 and 40 . However, by ensuring that a gap 36 in the inner conductive layer 35 is covered by a conductive segment from the outer barrier layer, the magnetic fields passing through the inner barrier layer create stronger eddy currents while passing through the outer barrier layer, therefore reducing their energy and reducing cable-to-cable crosstalk. Therefore, it is desirable to arrange the gaps 36 and 40 of the barrier layers to be aligned with conductive segments from an adjacent barrier layer; however, some gaps in the barrier layers may remain uncovered without significantly affecting the cable-to-cable crosstalk attenuation of the present invention.
FIG. 9 illustrates how the barrier tape 32 is spirally wound between the insulating layer 30 and the outer jacket 33 of the cable 22 . Alternatively, the barrier tape can be applied around the insulative layer in a non-helical way (e.g., cigarette or longitudinal style). It is desirable for the helical wrapping of the barrier tape 32 to have a wrap rate approximately equal to the core lay length of the cable 22 (i.e., the rate at which the twisted pairs 26 of the cable wrap around each other). However, in some embodiments the helical wrapping of the barrier tape 32 may have a wrap rate greater or less than the core lay length of the cable 22 .
FIG. 10 illustrates another embodiment of a barrier tape 60 according to the present invention that includes a third conductive layer with conductive segments 62 to specifically cover gaps 64 . Barrier tape 60 can have a structure similar to that shown in FIG. 4 , but with an additional barrier layer, and intervening substrate and glue layer, where the conductive segments 62 overlap gaps 64 as shown. The present invention is not limited to the embodiments shown, but can also include embodiments with a single barrier layer, or four or more barrier layers, in the barrier tape.
FIG. 11 illustrates another embodiment of a barrier tape 80 according to the present invention. The barrier tape 80 is similar to the barrier tape 32 shown and described above, except that the barrier tape 80 is provided with upper and lower rectangular conductive segments 82 and 83 . The rectangular segments on each layer are separated by gaps 84 . The rectangular conductive segments 82 and 83 have a longitudinal length 86 and a transverse width 88 . According to one embodiment, the longitudinal length 86 of each rectangular conductive segment 82 is approximately 822 mils, and the transverse width 88 is approximately 332 mils. In this embodiment, the gaps 84 are approximately 60 mils wide. As the conductive segment shape and size can be varied, so can the gap width. For example, the gap can be 55 mils or other widths. In general, the higher the ratio of the longitudinal lengths of the conductive segments to the gap widths, the better the crosstalk attenuation. Different dimensions may be provided, however, depending on the desired performance characteristics of the cable. The rectangular conductive segments 82 are provided with rounded corners 90 , and in the illustrated embodiment the rounded corners 90 have a radius of approximately 1/32″.
It is desirable for conductive segments according to the present invention to be provided with curved corners in order to reduce the chances of undesirable field effects that could arise if sharper corners are used. According to some embodiments of the present invention, curved corners having radii in the range of 10 mils to about 500 mils are preferable, though larger or smaller radii may be beneficial in certain embodiments.
FIG. 12 is a cross-sectional view of the barrier tape 80 taken along the line 12 - 12 of FIG. 11 . The barrier tape 80 comprises an insulative substrate 92 and upper and lower barrier layers 91 and 93 having rectangular conductive segments 82 and 83 . The rectangular conductive segments 82 and 83 are attached to the substrate 92 by a layer of spray glue 94 and are bordered by outer substrate layers 96 . According to one embodiment, the insulative substrate 92 has a thickness of about 1.5 mils, the spray glue layers 94 have thicknesses of approximately 0.5 mils, the conductive segments 82 and 83 have thicknesses of about 1 mil, and the outer substrate layers 96 have thicknesses of about 1 mil. Other thicknesses may be used for the layers depending on the desired physical and performance qualities of the barrier tape 80 .
FIG. 13 is a cross-sectional view of a cable 110 having an alternative twisted-pair divider 112 . The twisted-pair divider 112 has radial crossweb members 114 that extend outwardly from a center 116 of the divider 112 to circumferential crossweb members 118 . Twisted pairs 120 of the cable 110 are contained within open regions 122 bordered by the radial and circumferential crossweb members 114 and 118 . The circumferential crossweb members 118 serve as an inner insulating layer similar to the layer 30 of FIG. 2 . The twisted-pair divider 112 may incorporate a barrier layer comprising conductive segments, similar to the barrier tapes 32 , 60 , and 80 discussed above.
FIG. 14 is a cross-sectional view of another cable 124 having an alternative twisted-pair divider 126 . The twisted-pair divider 126 has radial crossweb members 128 that extend from a center 130 of the divider 126 and terminate at shortened circumferential crossweb members 132 . Twisted pairs 134 of the cable 124 are contained within open regions 136 partially bounded by the radial and shortened circumferential crossweb members 126 and 132 . The twisted-pair divider 126 may incorporate a barrier layer comprising conductive segments, similar to the barrier tapes 32 , 60 , and 80 discussed above.
FIG. 15 is a cross-sectional view of another cable 130 having an embossed film 132 as the insulating layer between the twisted wire pairs 26 and the barrier tape 32 . According to some embodiments, the embossed film 132 is in the form of an embossed tape made of a polymer such as polyethylene, polypropylene, or fluorinated ethylene propylene (FEP). In some embodiments, the embossed film 132 is made of an embossed layer of foamed polyethylene or polypropylene. Unfoamed fire-retardant polyethylene may be used as the base material. Embossing the film 132 provides for an insulating layer having a greater thickness than the thickness of the base material of the film. This produces a greater layer thickness per unit mass than non-embossed solid or foamed films. The incorporation of more air into the layer, via embossing, lowers the dielectric constant of the resulting layer, allowing for an overall lower cable diameter because the lower overall dielectric constant of the layer allows for a similar level of performance as a thicker layer of a material having a higher dielectric constant. The use of an embossed film reduces the overall cost of the cable by reducing the amount of solid material in the cable, and also improves the burn performance of the cable because a smaller amount of flammable material is provided within the cable than if a solid insulating layer is used. The use of an embossed film as the insulting layer has also been found to improve the insertion loss performance of the cable. Insulating layers according to the present invention may be spirally or otherwise wrapped around a cable core.
FIG. 16 is a cross-sectional view of a cable 134 having an embossed film 132 as the insulating layer between the twisted pairs 26 and the barrier tape 32 , and also having embossed films as separators between the individual twisted pairs 26 . The separators shown in FIG. 16 include a central straight separator 136 and a pair of bent separators 138 . Using embossed films as separators between the twisted wire pairs has many of the same advantages as using an embossed film as the insulating layer, as discussed above.
FIG. 17 is a plan view of one embodiment of an embossed film 132 . Side detail views S are also shown in FIG. 17 . In the embodiment shown in FIG. 17 , the embossed film 132 takes the form of a repeating pattern of embossed squares 140 in a base material such as polyethylene or polypropylene, either foamed or unfoamed. In a preferred embodiment, a foamed polymer film material is used. The aspect ratio of the embossed film 132 is the ratio between the effective thickness of the embossed film, t e , and the thickness of the base material, t b . Aspect ratios of up to 5, for example with a base material thickness of 3 mils and an effective thickness of 15 mils for the embossed film, are used according to some embodiments. Other useful ratios include a base material thickness of 3 mils and an effective thickness of 14 mils; a base material thickness of 5 mils and an effective thickness of 15 mils. According to some embodiments, base materials in the range of from 1.5 to 7 mils are embossed to effective thicknesses of from 8 mils to 20 mils. While embossed squares 140 are shown in FIG. 17 , other shapes may be used, as may a combination of different shapes over the length of the film 132 , including the use of patterned embossing.
Barrier tapes according to the present invention can be spirally, or otherwise, wrapped around individual twisted pairs within the cable to improve crosstalk attenuation between the twisted pairs. Further, barrier layers according to the present invention may be incorporated into different structures within a cable, including an insulating layer, an outer insulating jacket, or a twisted-pair divider structure.
From the foregoing, it can be seen that there have been provided features for improved performance of cables to increase attenuation of cable-to-cable crosstalk. While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. | 4y
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This application is a Continuation of application Ser. No. 08/662,106, filed Jun. 14, 1996, now abandoned, which is a Continuation, of application Ser. No. 08/289,046, filed Aug. 11, 1994, now abandoned.
This invention is related to the rinse solution that is used after the removal of the resist with alkaline solution during the fabrication of the semiconductor device. This rinse solution is considered superior because it does not cause corrosion of such wiring material as Al-Si-Cu frequently used as the wiring material in high-density integrated circuits.
BACKGROUND OF THE INVENTION
During the fabrication of the semiconductor device, after the desired photoresist mask is formed, the wiring pattern is formed by etching. Then the unnecessary resist layer, including the resist layer on top of the wiring pattern, is removed with the resist removal solution and cleaned with a rinse solution. Then it is necessary to use a rinsing process called water washing.
In such cases, as for the solution used to remove the resist, acidic or alkaline removal solutions can be named. As the representative of the acidic resist removal solution, the removal solutions obtained by mixing alkylbenzenesulfonic acid with phenol compounds, chlorinated solvents and aromatic hydrocarbons are sold commercially and used widely but, although such conventional solutions remove resists excellently, they have the problem of generating pit-shaped corrosion caused by alkylbenzenesulfonic acid on the surface of Al-Si-Cu wiring, which is widely used in high-density integrated circuits. In addition, the fact they contain phenol compounds, which are highly toxic, and chlorinated compounds, which can cause environmental pollution, presents a problems. Also, as for alkaline resist removal solution, the removal solutions composed of organic alkali and all kinds of organic solvents are sold commercially and used widely. Since these alkaline resist removal solutions have low toxicity and little effect on environmental pollution, they have been used extensively in recent years. However, although alkaline resist removal solutions exhibit the same excellent resist removal property as the above-mentioned acidic resist removal solutions, they have the problem of pitting the surface of the Al-Si-Cu wiring material by the alkaline component. This problem remains to be solved.
In order to solve the problem of generating pitting on the surface of the Al-Si-Cu wiring material by removing the resist with an alkaline solution, it has been determined, in accordance with the invention, that the this kind of corrosion is caused by the dissociation of alkaline components mixed into the rinse solution from the alkaline resist removal solution which is mixed in during the water rinse process carried out as the last removal process.
SUMMARY OF THE INVENTION
In accordance with the invention, the use of a noncorrosive rinse solution applied to the substrate which is characterized by the fact that the solution is composed of (a) a water-soluble monovalent lower alcohol and an organic or inorganic acid, or (b) a water-soluble monovalent lower alcohol, an organic or inorganic acid and water or (c) an organic or inorganic acid and water has been found to completely prevent this kind of corrosion.
In other words, this invention provides a noncorrosive rinse solution for application to the substrate, characterized by the fact that the solution to be used as the rinse solution after removal of the resist with alkaline solution is composed of (a) a water-soluble monovalent lower alcohol and an organic or inorganic acid, or (b) a water-soluble monovalent lower alcohol, an organic or inorganic acid and water or (c) an organic or inorganic acid. Also, this invention provides a semiconductor device fabricated by a method which includes rinsing of the substrate with the rinse solution after the resist has been removed. With the use of the rinse solution of this invention, the alkaline component that is mixed into the rinse solution from the alkaline resist removal solution is neutralized, and the corrosion of Al-Si-Cu wiring is prevented completely by suppressing the dissociation of the alkaline component during water washing. Therefore, the rinse solution of this invention exhibits superior properties, thereby making the fabrication of the high-precision and high-density circuit wiring possible.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view showing a model of each of the layers of a semiconductor substrate for the fabrication of of the semiconductor device.
FIG. 2 is a cross-sectional view showing a model of each of the layers of the semiconductor substrate for the fabrication of the semiconductor device.
FIG. 3 is a cross-sectional view showing a model of each of the layers of the semiconductor substrate for the fabrication of the semiconductor device.
FIG. 4 is a cross-sectional view showing a model of each of the layers of the semiconductor substrate for the fabrication of the semiconductor device.
Reference numerals as used in the drawings:
______________________________________1 Si substrate2 CVD oxidation film3 First metal film4 Second metal film5 Third metal film6 Positive-type photoresist7 Resist residue______________________________________
DESCRIPTION OF PREFERRED EMBODIMENTS
This invention will be explained in detail as follows:
As examples of water-soluble monovalent lower alcohols that can be used for the rinse solution of this invention, isopropyl alcohol, n-propyl alcohol, ethanol, methanol etc., can be listed. These can be used alone or as a combination of two or more kinds.
As examples of organic or inorganic acids that can be used for the rinse solution of this invention, acetic acid, sulfuric acid, oxalic acid, nitric acid, benzoic acid, dodecylbenzenesulfonic acid or their solutions can be listed. The amount of these acids used during mixing is the amount required to neutralize the alkaline component that is mixed in from the alkaline resist removal solution. If strong acids are added in excess, the acid will corrode the wiring during rinsing. Therefore, the amount added should be appropriate for the application. Also, as for the amount of water in the rinse solution, ordinarily, less than 50 wt % of the rinse solution is considered adequate. If 50 wt % or more is used, the alkaline component mixed into the rinse solution will dissociate easily, and Al-Si-Cu wiring will tend to be corroded easily in the rinse solution.
The rinse solution of this invention can be mixed with other components. As examples of such other components, a surfactant for the purpose of reducing the surface tension or preventing reattachment of the resist to the substrate etc., can be listed. Also, sugar compounds such as saccarides can be added.
Embodiments of this invention are given together with the comparative examples as follows.
Here, Table I shows the results of the microscopic evaluation of the number of pits generated by corrosion.
Embodiments and Comparative Examples
The compositions of the removal solution and the rinse solution used in the examples are shown in Table I.
A positive photoresist with a film thickness of 1.8 μm is coated after forming a two-layer TiW (bottom layer)/Al-Si-Cu (upper layer) film. The sample is then prebaked at 90° C. for 10 min in the oven. After resist patterning, postbaking is carried out at 140° C. for 30 min, and the wafer is immersed at 100° C. for 10 min in each removal solution. After removing the resist, the wafer is rinsed for 3 min in each rinse solution. It is then dried for 3 min drying after a water rinse for 3 min, and the number of pits generated by corrosion is evaluated using an optical microscope. These results are shown in Table I.
TABLE 1__________________________________________________________________________ Rinse Solution Component Alkaline Resist Component Other No. of Removal Than Acid Acid CorrosionExample Solution (wt %) (wt %) (mol/L) Pits__________________________________________________________________________1. DMSO/MEA/DMI -- Acetic Acid 0/mm.sup.2 (70/25/5)2. DMSO/MEA/DMI IPA Acetic Acid 0/mm.sup.2 (45/50/5) (0.00333)3. DMSO/MEA/DMI MeOH Acetic Acid 0/mm.sup.2 (45/50/5) (0.00333)4. DMSO/MEA/DMI EtOH Acetic Acid 0/mm.sup.2 (45/50/5) (0.00333)5. DMSO/MEA/DMI IPA Sulfuric Acid 0/mm.sup.2 (45/50/5) (0.00333)6. DMSO/MEA/DMI IPA Nitric Acid 0/mm.sup.2 (45/50/5) (0.00333)7. DMSO/MEA/DMI IPA Oxalic Acid 0/mm.sup.2 (45/50/5) (0.00333)8. DMSO/MEA/DMI IPA Benzoic Acid 0/mm.sup.2 (45/50/5) (0.00333)9. DMSO/MEA/DMI IPA Dodecylbene- 0/mm.sup.2 (45/50/5) zenesulfonic Acid (0.00333)10. DMSO/MEA/DMI IPA/Water Acetic Acid 0/mm.sup.2 (45/50/5) (80/20) (0.10000)11. DMSO/MEA/DMI IPA/Water/ Acetic Acid 0/mm.sup.2 (45/50/5) D-Sorbitol (0.00333) (50/30/20)12. KP-101 IPA Acetic Acid 0/mm.sup.2 Manufactured by (0.10000) Kanto Chemical13. KP-201 IPA Acetic Acid 0/mm.sup.2 Manufactured by (0.00333) Kanto ChemicalComparative DMSO/MEA/DMI IPA -- 1038/mm.sup.2Example (45/50/5)Comparative DMSO/MEA/DMI MeOH -- 392/mm.sup.2Example (45/50/5)Comparative DMSO/MEA/DMI EtOH -- 161/mm.sup.2Example (45/50/5)__________________________________________________________________________
Note:
DMSO: Dimethyl sulfoxide
MEA: Monoethanolamine
DMI: 1,3-Dimethyl-2-imidazolidinone
IPA: Isopropyl alcohol
MeOH: Methyl alcohol
EtOH: Ethyl alcohol
In the examples (Examples 1-13) in which the rinse solution of this invention was used, no corrosion of Al-Si-Cu was observed, whereas, with conventional solutions (Comparative Examples 1-3), the occurrence of corrosion was clearly recognized.
Embodiment Example 14
Next, a fabrication example of a semiconductor device using the rinse solution of this invention is explained, using FIGS. 1-3 as references.
First, CVD oxidation film 2, which is an insulation film, is formed on top of Si substrate 1. On top of this, TiW layer 3, which is the first metal film, CVD-W layer 4, which is the second metal film, and Al-Si-Cu layer 5, which is the third metal film, are formed in that sequence (see FIG. 1). The film thicknesses are 4,500 Å for the CVD oxidation film 2, 600 Å for the first metal film 3, 5,000 Å for the second metal film 4 and 8,000 Å for the third metal film 5. Also, Al-Si-Cu layer 5 contains 1 wt % Si and 0.5 wt % Cu.
A positive-type photoresist mask is formed by coating the surface of third metal film Al-Si-Cu layer 5 with the positive-type photoresist 6 and exposing it to the light (see FIG. 2). The main component of this positive-type photoresist is novolak resin, and its thickness is 18,000 9A. Baking is carried out at 140° C. for 30 min after the positive-type photoresist mask is formed.
Next, the region of the electroconductive layer not covered by the mask (nonmasked region) is removed by etching, and then the positive-type photoresist that has acted as a mask is removed by ashing (see FIG. 3). At that time, the residue of the resist remaining on the surface of the patterned electroconductive layer is removed using a removal solution composed of dimethyl sulfoxide:monoethanolamine:1,3-dimethyl-2-imidazolidinone=70:25:5 (wt %). The process is followed by washing with water after rinsing with a solution of isopropyl alcohol containing 0.333 mol/L acetic acid.
The rinse solution of this invention has a high cleaning power and does not corrode the Al-Si-Cu wiring material layer. As can be seen from the results shown in Table I, the number of pits generated by corrosion on the surface of the Al-Si-Cu layer clearly indicates that the rinse solution of this invention is better than the conventional solutions. Each component used in the rinse solution of this invention poses no danger to the human body from the handling standpoint and, therefore, the practical applicability is extremely high. | 4y
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division of U.S. application Ser. No. 09/150,707, filed Sep. 10, 1998, which was a continuation of International Application Ser. No. PCT/DE97/01239, filed Aug. 13, 1996, which designated the United States.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The invention relates to a process for producing a composite structural element, in particular for the body or parts of the body of a motor vehicle. The wall or structural element provides superior impact protection and increases the resistance to pressure and bending, and improves heat-insulation.
[0004] In the construction of motor vehicles for passenger transportation, occupant protection is becoming an increasingly important consideration. For example, the problem of side impact protection is solved by the installation of transverse members in the doors. As known, shock absorbers made of foam are also fitted into the cavities of the doors in order to distribute the forces occurring during impact and absorb impact energy by deforming. Side airbags are other known measures for the protection of vehicle occupants. However, the known configurations contribute only to a limited extent to the strength and rigidity of the body and consequently to the safety of the occupants.
[0005] A further problem of modern vehicle construction is that of heat insulation. More and more vehicles are being fitted with air-conditioning systems. At the same time, inadequate heat insulation results in wasted cooling energy on a large scale. Better heat insulation could make a considerable contribution to lowering energy consumption by reduced heating power in the winter and lower fan power in the summer.
SUMMARY OF THE INVENTION
[0006] It is accordingly an object of the invention to provide a process for producing a composite structural element which overcomes the above-mentioned disadvantages of the prior art devices and methods of this general type, and which provides a wall or structural element, preferably for the body or parts of the body of a motor vehicle, which offers the vehicle occupants a high level of safety during accidents and, by improved heat insulation, lowers energy consumption and improves traveling comfort.
[0007] With the foregoing and other objects in view there is provided, in accordance with the invention, a structural element for providing impact protection, increasing resistance to pressure and bending, and increasing heat-insulation, including a composite element having a sheet-like, thin-section wall part with a surface area; and a molding formed with a binder embedded with reinforcing elements and having a surface area adjoining the surface area of the sheet-like, thin section wall part, the composite element provided for dissipating impact forces and introducing the impact forces into load-bearing parts of a body.
[0008] The composite element formed in this way, which can be used variously as a wall element for the body or as a component for bumpers, members or the like, but also in other regions as a wall part or component of high flexural rigidity and heat insulation. The composite element can be produced at low cost and with little expenditure on primary raw materials. When used as a body wall element, it offers outstanding occupant protection during accidents, since the body or other components do not splinter and no sharp or broken edges causing injuries are produced. Any impact energy which is absorbed by the wall or structural element, such as doors, members, body panels, bumpers and the like, is dissipated and distributed over the surface area.
[0009] The expenditure on material for the body panel, in this case used as a sheet-like, thin-section wall part, is inexpensive. As a result, the vehicle weight can usually be reduced and consequently the energy consumption and ultimately the emission of pollutants can also be reduced. The climatic conditions in vehicles or other interior spaces provided with the wall element according to the invention can be improved considerably without having to use sophisticated air-conditioning systems.
[0010] In accordance with an added feature of the invention, the molding is either adhesively bonded over its entire surface area to the wall part or foamed onto the wall part.
[0011] In accordance with an additional feature of the invention, the reinforcing elements are renewable raw materials.
[0012] In accordance with another feature of the invention, the renewable raw materials are disposed in the binder as uncut, partially cut, and/or substantially cut in a form of stalks, stalk sections, fibers, bundles of fibers, twisted yarns, filaments, husks, nonwovens, wovens or rovings.
[0013] In accordance with another added feature of the invention, the renewable raw materials are dicotyledons, including flax, hemp, jute, and linume, and/or monocotyledons, including bamboo and giant grasses.
[0014] In accordance with another additional feature of the invention, the binder is a foamable synthetic, a biological derived substance, a naturally derived substance, matrices of natural substances or matrices of synthetic substances.
[0015] In accordance with yet another added feature of the invention, there are low weight recycled cores provided in regions of low tensile and compressive stress inside of the molding.
[0016] In accordance with yet another feature of the invention, the recycled cores are unreinforced recycled products, formed from foam, foam granules, preformed parts, prebonded parts, foam-textile combinations or textiles.
[0017] Inside the molding or in regions of low tensile and compressive stress, recycled cores of unreinforced or reinforced recycled products, such as foam, foam granules or preformed or prebonded parts of the latter, foam-textile combinations, textiles or natural foams, for example sunflower pith, may be provided.
[0018] In accordance with yet another additional feature of the invention, there is an insulating layer disposed between the molding and the thin-section wall part, the insulating layer is recycled foam and is adhesively bonded solidly to each of the molding and the thin-section wall part.
[0019] In accordance with yet a further added feature of the invention, the insulating layer includes a molded foam part, a foam panel or foam flakes.
[0020] In accordance with yet a further additional feature of the invention, a foamable material is admixed with the recycled foam forming the insulating layer for adhesively bonding the insulating layer with the thin-section wall part.
[0021] In accordance with yet another further feature of the invention, the molding is at least two moldings produced separately and bonded to one another in a sandwich type of construction.
[0022] In accordance with a further feature of the invention, each of the at least two moldings has a shell with a cavity formed therein, and the cavity receives an insulating core.
[0023] In accordance with an added feature of the invention, the insulating core is formed with the binder and the reinforcing elements.
[0024] In accordance with another feature of the invention, the insulating core includes recycled products without reinforcing elements.
[0025] In accordance with an additional feature of the invention, the insulating core has regions for receiving functional elements, actuating elements and cables.
[0026] In accordance with a further added feature of the invention, the molding is constructed at least partially from a number of shells in the sandwich type of construction for easy accessibility to and exchangeability of functional and actuating elements. Between the moldings there may be provided an insulating core composed of a binder and reinforcing means or composed of recycled products, it also being possible for clearances to be formed in the insulating core for receiving actuating elements, cables or the like.
[0027] In accordance with a further additional feature of the invention, the thin-section wall part is formed with sheet metal or a thin-layer, sheet-like decorative material.
[0028] In accordance with yet another added feature of the invention, the wall part is formed with sheet metal for forming a sheet-metal skin, and includes a hard shell formed by compression molding or injection molding adjoined to and reinforcing the sheet-metal skin, the hard shell also adjoining and solidly bonding to the molding.
[0029] In accordance with yet another feature of the invention, the hard shell includes the reinforcing elements for providing high tensile stress strength.
[0030] In accordance with yet another additional feature of the invention, the molding is adjoined on two sides by the hard shell. Between the thin-section wall part and the molding there is arranged a hard shell formed by compression molding or injection molding and solidly bonded to both of them. The molding may be covered on the side opposite the wall part by a solidly bonded second hard shell, as a counter-chord. Cross-pieces extending in the transverse direction may also be molded onto the first hard shell, the cavities formed as a result are filled in the way described above with reinforcing elements or recycled products, or both, surrounded by binder.
[0031] In accordance with an added feature of the invention, the hard shell covered molding includes at least one recycled core.
[0032] In accordance with another feature of the invention, there are transverse cross-pieces extending in a transverse direction which are molded onto the hard shell adjoining the wall part.
[0033] In accordance with an additional feature of the invention, the hard shell provided with the transverse cross-pieces is formed from a plurality of half-shells which are solidly bonded to the wall part and to one another.
[0034] In accordance with a further added feature of the invention, the half-shells have cavities formed therein, the cavities of the half-shells are filled with one of the reinforcing elements and the binder, unreinforced recycled material, and the reinforcing elements and the binder with a recycled core.
[0035] In accordance with a further feature of the invention, the composite element is one of a body part or parts of the body of a motor vehicle.
[0036] With the foregoing and other objects in view there is also provided, in accordance with the invention, a process for producing a composite structural element, which includes providing a thin-section wall part; placing the thin-section wall part into a mold; applying reinforcing elements to the thin-section wall part; placing a counter-mold onto the mold for forming a mold cavity; introducing a binder having a foaming agent into the mold cavity via one of injection cannulas and nozzles, after a set time delay a foaming of the binder occurring for encapsulating the reinforcing elements on all sides.
[0037] According to the process of the invention for producing the structural element as a composite work piece, reinforcing elements, preferably in the form of renewable raw materials or parts thereof, are applied to the thin-section wall element, preferably consisting of sheet metal, and, after the placing on of a counter-mold, the binder with a delayed-action or immediately acting foaming agent are introduced into the cavity thus formed via injection cannulas or nozzles. The binder initially flows around the reinforcing elements, in order to create during the subsequent foaming a solid bond between the wall part and the foamed binder and between the reinforcing elements and the foamed binder and at the same time to fix the reinforcing elements in position. To improve the adhesion between the wall part and the molding formed of the binder and reinforcing elements, the side of the wall part facing the molding may be primed in advance.
[0038] Before providing the reinforcing elements, the thin-section wall part may be backed with a hard shell by compression molding or injection molding, a second hard shell being applied as a counter-chord once the molding has formed.
[0039] The first hard shell—provided with transverse cross-pieces—may be produced separately and also in more than one part and then be adhesively bonded on the wall part in an already prefabricated form. A plurality of hard shells with transverse cross-pieces also being held in positive engagement with respect to one another and on the wall part may also form one complete hard shell.
[0040] In accordance with an added feature of the invention, there is the further step of introducing the binder having the foaming agent into an open mold.
[0041] In accordance with another feature of the invention, there is the further step of using the binder with the foaming agent having a set time delay of less than 5 seconds for foaming the binder.
[0042] In accordance with an additional feature of the invention, there is the step of priming the thin-section wall part on a foam application side to improve adhesion before applying the binder.
[0043] In accordance with yet another added feature of the invention, there is the step of backing the thin-section wall part with a hard shell formed with reinforcing elements by compression molding or injection molding before a formation of the mold cavity, and applying a second hard shell subsequently to the free side of the molding.
[0044] In accordance with yet another further feature of the invention, there is the step of molding on transverse crosspieces to the hard shell during the application of the hard shell.
[0045] In accordance with yet a further feature of the invention, there is the step of forming a recycled core from one of a foam or a comparable light weight material and placing the recycled core in the reinforcing elements before the binder is injected.
[0046] With the foregoing and other objects in view there is further provided, in accordance with the invention, a process for producing a composite structural element, which includes: producing moldings formed with reinforcing elements and a binder by foaming of the binder for encapsulating the reinforcing elements; producing hard shells formed with the reinforcing elements and the binder by foaming of the binder for encapsulating the reinforcing elements; and providing a thin-section wall part, and bonding adhesively the moldings and the hard shells to the thin-section wall part for forming a composite element. The moldings themselves may also be produced separately from the thin-section wall part, to be precise with or without recycled cores, and then be adhesively bonded to the wall part or to the hard shell.
[0047] In accordance with an added feature of the invention, there is the step of producing the moldings with recycled cores.
[0048] In accordance with a concomitant feature of the invention, there is the step of producing the hard shells with transverse cross-pieces.
[0049] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0050] Although the invention is illustrated and described herein as embodied in a process for producing a composite structural element, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0051] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] [0052]FIG. 1 is a sectional view of a wall or structural element of a composite type of construction bonded to a further composite component, taking as an example a vehicle door of a motor vehicle according to the invention;
[0053] [0053]FIG. 2 is a sectional view of a second embodiment of the structural element serving as the vehicle door;
[0054] [0054]FIG. 3 is a sectional view of a third embodiment of the structural element of the composite type used as part of the vehicle door connected to a second composite component; and
[0055] [0055]FIGS. 4 a and 4 b are perspective, side-elevational views of the vehicle door and of load-bearing parts of a passenger car in a region of the vehicle door, with arrows representing dissipation to all sides of forces generated during side impact onto the load-bearing parts of the vehicle door and of a body of the motor vehicle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0056] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a wall or structural element produced as a composite in the example of a door for a motor vehicle. The door includes two wall or structural elements respectively produced as a composite type of construction and secured to each other, but leaving a channel 5 free between them because of a required fitting of a window pane 6 and a mechanism required for moving it. A thin-section wall part 1 for an outer skin of the motor vehicle door is formed of sheet metal, is adjoined by a molding 4 formed of a foamed synthetic, biological or naturally derived binder 2 and reinforcing elements 3 surrounding the latter and thereby fixed in their position. The molding 4 is bonded to a second molding 4 a , or composite part, forming an interior paneling of the vehicle door. Provided between the two moldings 4 , 4 a is the channel 5 for receiving the window pane 6 , a guide rail 7 required for guiding the window pane 6 , and further actuating elements (not shown in the drawing) for moving the window pane 6 . The outside of the second molding 4 a is covered by a decorative layer 8 shown as a thin-layered wall part and is solidly bonded to the molding 4 a by foaming on, adhesion or the like. The production of the wall or structural element shown in FIG. 1 takes place by placing the wall part 1 , serving as the outer door skin formed of sheet metal, into a mold and covering its inner side uniformly with a layer of the reinforcing element 3 . Renewable raw materials in the form of stalks and stalk sections or fibers and bundles of fibers as well as nonwovens and the like produced from the latter are used as the reinforcing elements 3 . Preferably considered here as renewable raw materials are monocotyledons and dicotyledons, which are distinguished by outstanding mechanical properties. In the case of dicotyledons, the periphery of the stalk consists of a bast ring, which is composed of extremely long and high-strength fibers, particularly in the case of bast fiber plants. The cylindrical arrangement of the bast fibers represents what is mechanically an ideal cross section for bringing about a particularly high modulus of elasticity as well as a high flexural strength and buckling resistance. Although monocotyledons do not have a pronounced bast ring, they have a ring of shorter-fibered sclerenchyma, adjoined in the case of many species by a high-strength ring of vascular bundles, which are accompanied by high-strength mechanical tissue. In addition to this, they have a highly pronounced epidermis of great toughness.
[0057] The renewable raw materials used according to the invention are also advantageous to the extent that their fibers are embedded in a parenchyma matrix. The parenchyma is resistant to pressure and has a large lumen and, in interaction with the peripheral strengthening strands, allows considerable flexing. In the case of dicotyledons, on the other hand, in the center of the stalk there is instead of the parenchyma a core of wood, which is likewise characterized by an extremely low wood density.
[0058] After applying the reinforcing elements 3 of renewable raw materials to the wall part 1 , a counter-mold (not shown) is placed on and the binder 2 is introduced via corresponding cannulas or injection nozzles into the hollow mold thus formed. The binder 2 is free-flowing during injection process, with the result that it flows completely around the reinforcing elements 3 and can penetrate into all the intermediate spaces. After a time delay, the binder 2 will foam and secure the reinforcing elements 3 in place. The foaming process commences only after a certain time delay after a corresponding distribution of the binder 2 . The foamed binder 2 adheres solidly to the reinforcing elements 3 and fixing the latter in its position.
[0059] Once the inner side of the wall parts 1 (door panel) has been primed, if need be, before being placed into the mold, the molding 4 including the foamed binder 2 and reinforcing elements 3 also undergoes a solidly adhering, full-area bond with the wall part 1 . The result being a one-piece composite is obtained after removing the counter-mold.
[0060] In the case of the exemplary embodiment represented on the basis of a vehicle door, the second molding 4 a can be separately produced in the same way as a thin-section wall part 1 onto an interior paneling or the decorative layer 8 .
[0061] The two composite parts subsequently being solidly bonded to each other in a sandwich-like manner with recesses forming intermediate spaces for receiving the window pane 6 and necessary guiding and actuating elements.
[0062] With composites produced in this way, which may be configured equally as a member or a wall element of the body or as a bumper etc., outstanding side impact protection in the motor vehicle is achieved by increasing the moment of resistance and the deformation path. Since impact forces are uniformly distributed and dissipated and introduced into the cage structure of the passenger compartment, the impact energy is substantially absorbed. At the same time, the heat insulation of the body is improved and consequently the CO 2 emission and the energy consumption are reduced. Finally, the climatic conditions in the interior of the vehicle are also improved. On account of the composite type of construction including a sheet-like wall part 1 and the reinforced molding 4 (foam element), the body panel can be made much thinner than is generally customary, with the result that the expenditure on material for the body panel, which is a high consumer of primary energy, and ultimately the weight of the body can usually be lowered. In addition, in the event of impact, no sharp edges are produced, since the composite material does not splinter, and consequently the safety of the vehicle occupants and other persons involved in an accident is increased.
[0063] According to the invention, it is also possible, however, contrary to the production process described above, to produce the reinforced molding 4 , 4 a separately in a mold, i.e. separately from the wall part 1 (or 8 ), and subsequently adhesively bond it to the thin-section wall part 1 . Even greater rigidity of the structural element produced as a composite part can be achieved by using integral foam, it being possible in this case to reduce further the wall thickness of the thin-section wall part 1 .
[0064] [0064]FIG. 2 shows a second variant of the invention also shown by example as the door of a motor vehicle in which the impact protection is further improved and the thickness of the wall part 1 is even further reduced.
[0065] The wall part or component differs from that represented in FIG. 1 essentially in that the thin-section wall part 1 , i.e. the outer skin of the door, the body, a member etc., is backed by a hard shell or insulating layer 9 formed by compression molding or injection molding 9 , preferably using reinforcing elements 3 of renewable raw materials in the hard shell 9 . In the way described above, the molding 4 including the reinforced foam or integral foam and reinforcing elements 3 are applied to the hard shell 9 , in a solid bond with the shell 9 , and a further hard shell 9 is applied to the molding 4 as a counter-chord.
[0066] It can also be seen from FIG. 2 that, to save primary material, inside the molding 4 there is a recycled core or insulating core 10 formed of a lightweight recycled material. The size of this recycled core 10 is variable. It may ultimately reach over the entire cross section of the molding 4 and, moreover, be reinforced with renewable raw materials or other materials. It goes without saying that this molding can also be produced separately, as described with reference to FIG. 1, and then be adhesively bonded to the thin-section wall part 1 , in order to form the composite in this way. In order to form the channel 5 , the second molding 4 a , or the second structural element, is solidly joined onto the structural element thus formed.
[0067] In FIG. 3, there is reproduced a third variant of a wall or structural element, configured as a composite, for the motor vehicle door. In this case, the wall or structural element is reinforced by transverse cross-pieces 11 a , which are part of half-shells 11 produced separately and solidly bonded to the wall part 1 . The half-shells 11 are placed with positive engagement into the wall part 1 and held against the latter and with respect to one another by adhesion or foaming in.
[0068] The half-shells 11 with the transverse cross-pieces 11 a extending substantially perpendicularly away from the latter, are produced with the preferred use of renewable raw materials as reinforcing elements 3 . The cavities formed by the half-shells 11 and transverse cross-pieces 11 a are filled by reinforcing elements 3 composed of renewable raw materials and foam having a binder 2 , or else are provided with a recycled core or completely with a foam filling. The half-shells 11 filled in this way are covered with a hard shell 9 . The hard shell 9 forms a solid bond with the half-shells 11 or the transverse cross-pieces 11 a , for example by the foam-filling of the cavities. The hard shells 9 and the half-shells 11 are produced by a compression-molding technique or else an injection-molding or blow-molding technique, with or without the use of reinforcing elements 3 .
[0069] With the third variant, particularly high rigidity and flexural strength can be achieved resulting in a further reduction in the material thickness of the outer skin (wall part 1 ).
[0070] As already described above, the composite element embodiments may be in the form of a vehicle door. There may be connected to the composite element thus produced, the second molding 4 a , into which various functional elements (not shown), such as map pockets, armrests or the like, may be integrated. In this case, the thin-section inner wall part (decorative layer 8 ) may also be configured as a thin sheet-metal skin, in 20 order to bring about a further increase in the rigidity of the vehicle door.
[0071] It can be seen from the representations of a passenger vehicle door, or the part of the body receiving the latter, reproduced in FIGS. 4 a and 4 b , how the door in the form of a rigid shell covers over the fold of the door opening over its full area—with the exception of the window region—and consequently the energy generated during impact (large arrow) is dissipated over a large area onto the entire door fold in the direction of the small arrows. In addition, in combination with the dissipation of the forces, the impact energy is absorbed by the compression of the foam core extending over the entire door surface area. | 4y
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BACKGROUND OF THE INVENTION
The present invention relates to a tire tread design, especially for use on motorcycle tires.
Tire designers are continually seeking to improve on previous tread designs to optimize often conflicting performance requirements. A primary requirement for a suitable tire tread design is adequate clearance of water from the portion of the tread which contacts the road surface, i.e., the contact patch, to prevent hydroplaning and provide such handling on wet roads. The tread design should also have minimum sensitivity to road surface characteristics and must also have an adequate braking capability under both wet and dry conditions. The tread design should also reduce tread wear as much as possible.
For water clearance, various groove designs have been provided in tire treads to remove water from the contact patch. In most cases, water removing grooves run continuously and circumferentially of the tire. Unfortunately, a continuous circumferentially extending water removing groove can cause problems when the contact patch area is relatively narrow, such as occurs in a motorcycle tire which has a narrow rounded tread profile, as the groove can engage with and be guided by longitudinally extending areas of a road surface, such as rain grooves, joints and lane marking strips. On a road surface provided with such rain grooves, joints or lane marking strips, it is possible for a water channeling groove on the tire tread to follow the road surface characteristic instead of the command of a motorcycle rider, causing problems with driver control. Turning the wheel to dislodge a tire from a road surface characteristic can be difficult, requiring a jerking turning motion which may result in an unsafe operation of the motorcycle.
SUMMARY OF THE INVENTION
The present invention was designed to provide a unique tire tread construction which provides adequate water removal from the contact patch area while maximizing other desirable tread characteristics and improving driver control.
Accordingly, one object of the present invention is the provision of a tire tread pattern having a generally diagonal groove construction permitting improved water clearance from the contact patch, without providing a groove which runs continuously circumferentially of the tire. The diagonally oriented groove construction eliminates the possibility of the water channeling grooves locking onto and thus following longitudinal grooves, joints or lane marking strips provided on a road surface.
Another object of the invention is the provision of a tire tread pattern in which standing water in the contact patch is removed by the diagonally running water channeling grooves, while the edges of the water channeling grooves themselves and additional sipes and wedge grooves provided in the tread cut any remaining water film to provide a solid tire to road contact patch.
Another object of the invention is the provision of a tire tread pattern having generally diagonal water channeling grooves which cooperate with other circumferentially running water channeling grooves to provide a high degree of water removal from the contact patch area during both straight running of the tire as well as running on a portion of the tread adjacent the sidewall, such as occurs during hard turning of a motorcycle.
Another object of the invention is the provision of a tire tread pattern as above which is highly effective in removing water from the contact path area and which further includes additional circumferentially spaced holes or additional siping in the tread for absorbing minute water particles remaining at the contact patch area thereby maximizing gripping of the tread to the road surface.
Another object of the invention is the provision of a tire tread pattern as above having a high ratio of contact surface area to groove area which increases braking friction and allows the tire load and torque to be distributed more evenly over a larger area.
Another object of the invention is the provision of a tire tread pattern as above which provides large unbroken tread blocks to stabilize the contact patch thus reducing tread pattern squirm.
These and other objects and advantages of the tire tread construction of the invention will be more clearly seen from a detailed description which follows which is taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates in perspective view a motorcycle tire incorporating the tread construction of the invention;
FIG. 2 shows a front view of a portion of the tire tread illustrated in FIG. 1;
FIG. 3 illustrates a sectional view taken along the line 3--3 in FIG. 2;
FIG. 4 illustrates a sectional view taken along the line 4--4 in FIG. 2;
FIG. 5 illustrates a sectional view taken along the line 5--5 in FIG. 2;
FIG. 6 illustrates a sectional view taken along the line 6--6 in FIG. 2; and
FIG. 7 shows a front view of a portion of tire tread having a modified tread construction.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 show a tread portion 11 of a tire connected to sidewalls 13. Tread portion 11 contains a plurality of generally diagonally extending water channeling grooves 17 which run from one side of the tread portion to the other. The water channeling grooves 17 define between them a plurality of road-contacting tread blocks 15. The generally diagonal water channeling grooves ensure the absence of a continuous groove running circumferentially of the tire and prevent the tire from locking onto a longitudinally oriented road characteristic which might direct or deflect the travel path of the tire. The water channeling grooves 17 each comprise an intermediate portion 19 which runs in the circumferential direction of a tire and diagonal portions 18 running in zig-zag fashion from each of the opposite ends of the intermediate portions 19 to respective edges of the tread. Each of the diagonal portions 18 is formed by three connected groove segments 18a, 18b and 18c. Segments 18a and 18c are angled approximately 40° from the circumferential center line of the tire, while segment 18b is angled approximately 70° from the circumferential center line. The intermediate portions 19 of grooves 17 align in a circumferential direction of the tire in the center of tread portion 11 and are separated by portions of the blocks 15 defined by adjacent grooves 17.
A pair of water channeling grooves 29 are also provided adjacent respective edges of the tire tread portion 11. These grooves run circumferentially of the tire in a zig-zag pattern. The terminating ends of the diagonal water channeling grooves 17 (that is the terminating ends of groove portions 18 running from the intermediate portions 19) are respectively connected with the grooves 29.
The grooves 29 have successive circumferentially extending groove portions 31 and 33 which are connected by substantially V-shaped groove portions 35. The legs 35a, 35b of U-shaped portion 35 are angled approximately 40° from the circumferential center line of the tire. The successive circumferentially extending groove portions 31 and 33 are offset from one another by substantially the width of the second groove 29. The offsetting of the circumferentially extending second groove portions 31 and 33 and their interconnection by the substantially V-shaped groove portion 35 insures the absence of a straight groove pattern running circumferentially of the tire to prevent locking of the second grooves 29 with a longitudinal roadway surface characteristic when the tire is running adjacent the edges of the tread.
As clearly recognized, water in the contact patch area of the tread, that is substantially in the middle of the tread portion is effectively conducted away by the grooves 17. In addition, water is conducted away from the grooves 17 into the grooves 29 which are connected to the opposite ends of the grooves 17. Additional water channeling away from the second grooves 29 to the edge of the tread is provided by grooves 21 which interconnect with grooves 29 and are regularly spaced at the edges of the tread circumferentially around the tire. The grooves 21 are each formed of first shallower but wider grooves 23 and second deeper but narrower tunnel like grooves 25, as more clearly illustrated in FIG. 4. At the terminus of the grooves 21 is a flared portion 27 having a ribbed surface, as more clearly illustrated in FIG. 6.
The blocks 15 defined by adjacent diagonal grooves 17 are further broken into smaller blocks by narrow siping grooves 37. The siping grooves 37 are much narrower than water channeling grooves 17, 21 and 29. The siping grooves increase the compliance of the tread by diminishing the size of the tread blocks. They also absorb water at the contact patch area, and provide additional road gripping edges. Additional siping grooves 39 are also provided within the blocks 15 for the same reason. Although the siping grooves 37 are arranged to sub-divide the blocks 15, substantial portions of the blocks 15 at the central portion of the tread 11 remain undivided to provide a large unbroken road contacting surface which reduces tread pattern squirm.
As further illustrated in FIGS. 1 and 2, additional V-shaped grooves 43 are provided within the blocks 15 and spaced along the circumference of the tire on opposite sides of the center of the tread. The angle between the legs 43a and 43b of the V-shaped grooves is approximately 100°. These additional V-shaped grooves also collect water which may be present in the contact patch area, add compliance to the tread surface, provide additional edges which facilitate gripping of the tread to a road surface and also dissipate heat.
Holes 41 may also provided within the blocks 15 along the circumferential extent of the tire. Holes 41 absorb minute water droplets at the contact patch area. The holes first fill with water droplets and air is compressed between the droplets residing in the holes and the road surface. The holes effectively act as gripping cells which provide added traction on a road surface. The air retained in the holes at the contact patch area also provides additional compliance to the tread pattern thus further assisting in tire gripping and braking action.
The spacing of the holes to each other and to other grooved areas of the tire is at least one quarter of an inch (1/4") to insure the holes will not tear into each other to other structures upon the application of force to the tire tread such as during breaking and quick acceleration. In lieu of holes 41, additional siping grooves 51, similar to grooves, 37, can be provided in the tread at substantially the same circumferential position as holes 41, as illustrated in FIG. 7.
Additional V-shaped siping grooves 45 may be provided between the sidewall 13 of the tire and the pair of grooves 29 which are adjacent respective edges of the tread pattern. These siping grooves also serve to break up larger blocks of tread material adjacent the tread edges and additionally absorb small water droplets, dissipate heat, and provide additional edges to assure gripping of the tire tread to the road surface upon cornering. FIG. 7 shows the alternative use of angled siping grooves at the tread edges in place of the V-shaped siping grooves 45 illustrated in FIGS. 1 and 2.
As also illustrated in FIGS. 1 and 2 the water channeling grooves 17, 21, 29 and the siping and V-shaped grooves 37, 39 and 43 occupy a relatively small area as compared to the land areas formed by the tread blocks 15 thus ensuring a high degree of braking friction and the distribution of tire load and torque over a large area.
The tire construction as shown and described, obtains improved water removal from the contact patch area while eliminating continuous straight grooves running circumferentially of the tire. This insures that the tire tread, particularly that of a motorcycle tire, will not lock onto any longitudinal grooves, joints or lane markings provided in a road surface. In addition, the pattern as illustrated effectively channels water away from the contact patch area while providing enhanced compliance to the tread surface to insure better gripping of the tread to the road surface. The pattern also provides a large number of groove edges to further improve tire gripping.
Although preferred embodiments of the tire tread have been described and illustrated, it should be understood that various modifications can be made thereto without departing from the spirit and scope of the invention. Accordingly, the invention is not limited by the foregoing description, but it is only limited by the claims appended hereto. | 4y
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BACKGROUND
[0001] This invention relates to separable fasteners, in general, and, in specific, to separable fasteners that will be attached to a molded article, such as a seat cushion.
[0002] One portion of such a separable fastener is typically incorporated into the molded object, such as a polyurethane seating foam, during a molding process, for subsequent attachment to another object carrying the mating portion of the separable fastener. The fastener of this invention greatly simplifies the method of molding the part to which it is attached. Although particular reference is made herein to elastomeric polyurethane foam or hard plastic parts, it is to be understood that a fastener product according to this invention can be used in parts made from a wide variety of materials, e.g. thermoplastic materials, thermoset materials, elastomers, or any other-moldable composition.
[0003] Hook and loop separable fasteners,-such as those sold by the assignee of this invention under the trademarks “VELCRO” and “ULTRAMATE,” are well known and used to join two members detachably to each other. This type of fastener has two components. Each has a flexible substrate or base having one component of the fastening system on the surface thereof. One surface typically carries resilient hooks while the other carries loops. When the two surfaces are pressed together they interlock to form a releasable engagement.
[0004] The hooks can be any of a variety of shapes, including cane-shaped, palm tree-shaped and mushroom-shaped, all of which are well known within the art. As used within this application, the terms “hook,” “hook-type” and “hook-like” shall be construed to mean any such configuration of loop-engaging element.
[0005] Separable fasteners are used in the manufacture of automobile seats in the attachment of an upholstered seat cover, (“trim cover”), to a polyurethane foam bun. One portion of the separable fastener is incorporated into the surface of the polyurethane seat bun during the foam molding process. The mating portion of the separable fastener is attached to the seat cover to provide releasable attachment to the foam seat bun. The separable fastener assembly used in the foam mold for incorporation in the bun surface typically is the hooked portion of the separable fastener system. This hook portion has a base carrying resilient hooks on one surface. The surface of the base obverse of the hook-carrying surface may act as an anchoring surface by a variety of configurations well known in the art.
[0006] In some assemblies a magnetically attractive material is attached to the base to facilitate placement of the assembly in a trough of the mold cavity wall, which is equipped with magnets. It is also possible to incorporate magnetically attractive material into the body of the fastener itself, such as in a plastic material that is used to make the fastener. This is described in detail in U.S. Pat. No. 5,725,928, issued on Mar. 10, 1998, entitled TOUCH FASTENER WITH MAGNETIC ATTRACTANT, assigned to Velcro Industries B.V., inventors, Brian J. Routhier, Randall B. Kenney and Martin I. Jacobs, the disclosure of which is hereby incorporated herein by reference.
[0007] Such fastening devices are applied to one surface of a clamshell mold; a chemical mixture, for instance of a diisocyanate and a polyol, is injected into a mold; the upper surface of the mold is closed and clamped shut while the chemicals react and blow to form a flexible foam, well known in the art.
[0008] A protective layer, often in the form of a thin plastic film, may be placed over the resilient hooks (before they are placed in the mold) to prevent incursion of foam into the hooks during the molding process. Significant foam contamination of the hooks would diminish their ability to engage with the mating portion of the fastener.
[0009] Prior-art assemblies, including those disclosed in U.S. Pat. Nos. 4,673,542, inventor Wigner et al., 4,563,380, inventor Black et al., and 4,693,921, inventor Billarant et al., employ a thin, enveloping film to prevent the incursion of foam into the fastener elements of the separable fastener during molding. French Patent 2,423,666 discloses a system for sealing the edges of the tape in the mold trough by jamming the edges of the fastener into the trough.
[0010] Two patents, which are assigned to the assignee hereof, disclose another arrangement for protecting the fastening elements from degradation and fouling by the foaming material. U.S. Pat. No. 5,286,431, issued on Feb. 15, 1994, to Banfield and Rocha, entitled MOLDED PRODUCT HAVING INSERT MOLD-IN FASTENER, discloses a fastener of the hook and loop type having a base member and a plurality of engaging elements upstanding from one surface thereof. A flexible (e.g. elastomeric or rubber) encasement (which may be either thermoplastic or thermoset) that intimately surrounds the individual engaging elements, substantially filling all of the space around each one, protects the elements when they are exposed to the harsh environment of a molding process. The fastener is placed in a mold and molded into, as an integral part thereof, a molded part. The encasement is removable from the engaging elements after the molding process, to expose the engaging elements, without permanently deforming or substantially destroying the fastening performance thereof. U.S. Pat. No. 5,540,970, issued on Jul. 30, 1996 to Banfield et al., entitled DIE CUT MOLD-IN, further discloses providing the flexible cover so that the tips of the hooks are slightly exposed. Other modifications of the invention are shown in the '970 patent as well. The disclosures of both of these patents are incorporated fully herein by reference.
[0011] All of the arrangements discussed above that entail covering the fastening elements that are to be used to attach the molded product to a trim cover or companion piece, require that the molding operation include a step to remove the protective cover, be it a film-like cover or a space filling, encasing cover. This entails an inconvenience for the molding operator. Further, once removed, the cover is in the possession of the molding operator, who must dispose of it. But, the molding operator is not the one who could reuse the cover, even if it were to be recyclable. (It is the fastener manufacturer who is in the best position to reuse the cover.) Thus, from the perspective of the molding operator, it is very beneficial to be able to use a fastening component that does not require a removable cover. Consequently, those whose business it is to make the fastening component to be incorporated into the molded article are interested in providing to the molding operator a component that does not have a cover that needs to be removed after molding.
[0012] It is also typically desirable to avoid any apparatus that can not be used with a conventional mold, having a simple flat bottom trench for placement of the fastening element. Otherwise, the molding operator must alter its normal equipment and way of doing business.
[0013] Thus, there are so called “coverless” products, which protect the fasteners without a separate cover. One such product is described in U.S. Pat. No. 5,606,781, issued on Mar. 4, 1997, entitled, SEPARABLE FASTENER HAVING A BALD PERIMETER RIB BOUNDED BY FASTENING ELEMENTS, also assigned to the assignee hereof, inventors, George Provost, Brian J. Routhier and Martin I. Jacobs. This product has a fastener with a central fastening area of fastening elements, surrounded by a region that has no hooks (into which a mating portion of the mold may fit) which is in turn surrounded by a ring of fastening elements that are “sacrificial,” in the sense that they may become fouled with molding material, but they will prevent the incursion of the molding material into the interior, fastening area. The disclosure of this '781 patent is hereby incorporated herein by reference.
[0014] U.S. Pat. No. 5,786,061, issued on Jul. 28, 1998, to the present assignee, entitled SEPARABLE FASTENER HAVING A PERIMETER COVER GASKET, inventor Donald Banfield, discloses a fastener having a flexible, space filling cover as described above in connection with either Pat. Nos. 5,286,431 or 5,540,970, but where the gasket covers only the perimeter hooks, with an internal coverless region. This gasket cover can remain on the fastening element after the molding operation has completed, thereby eliminating the need to dispose of a removed cover.
[0015] Other patents that disclose a gasket type approach to this problem are those assigned to Velcro Industries B.V., in the name of Hatch, including, Pat. Nos. 4,726,975 and 4,814,036, which describe a flexible sealing lip that is applied along the elongated marginal edges of a fastening element. Also of interest is U.S. Pat. No. 4,842,916, assigned to Kuraray Company, Ltd., inventor Ogawa, which describe gaskets of fiber, and, in some cases, foam.
[0016] Another challenge to using fasteners of the type described above in connection with molded products, foam or otherwise, is that it is often desirable to attach the fastener to a contoured surface, perhaps one that curves through three dimensions. All of the fasteners described above, in their basic configuration, are made as continuous elongated rectangular sheets, which are typically used as is, or stripped into narrower strips, all of which remain basically rectilinear.
[0017] Such narrow strips can be bent, relatively easily, through two dimensions, out of the plane of the strip. However, bending in the plane of the strip would result in creasing or puckering, as would bending around two or more axis in three dimensions. Bending is further complicated by some of the covering schemes disclosed above, as bending may cause the cover to buckle or separate from the substrate, and thus to fail for its intended purpose.
[0018] It is possible with some, but not all of the designs discussed above, to make large planar sheets and cut any shape desired therefrom. However, this procedure typically results in a relatively high amount of waste material. Further, one is still presented with a basically flat piece of material that must be bent to fit a contoured shape. Another possible solution, is to use numerous separate relatively small fasteners, each of which must be separately placed in and fixed to the mold. This is undesireable because it requires significant operator handwork or specialized machinery.
[0019] Thus, the several objectives of the invention include to provide a fastener that can be secured to the surface of a molded object having virtually any contour, without requiring special cutting of shapes, or placing separate fasteners, and without significant waste of material, and time. Another objective of the present invention is to provide a fastener that has an integral barrier against foam intrusion, which economically, simply and securely protects the fastening elements from being fouled by foaming material. It is a further objective of the invention to provide both the contour and foam barrier features in the same product, without the solution to one problem limiting the effectiveness of the solution to the other.
SUMMARY
[0020] In general, according to the present invention, a segmented fastener is used to accommodate molding contours. Each segment may be surrounded by a gasket barrier, or covered by another sort of cover, or left unprotected.
[0021] A preferred embodiment of the invention is a separable fastener component for use with a complementary separable fastener component. The separable fastener component comprises a plurality of fastening segments. Each fastening segment comprises a base member, having a nominal fastening face and a non-fastening face; and carried on the fastening face of the base member, a plurality of fastening elements, either hook-type or loop-type. Located between and joining each adjacent pair of fastening segments is a flexible neck that is narrower than the fastening segment. The flexible neck region is typically flexible around two or three orthogonal axes.
[0022] For each of the fastening segments, there may be a barrier for use during an operation to incorporate the fastener into a molded body, using a mold having a wall, which barrier would prevent any liquid foaming material from contacting a major portion of any of the fastening elements if the fastener is placed in the mold with the fastening elements pressed against the wall of the mold. The cover may be an enveloping type, or a space filling type, that substantially fills any spaces among the fastening elements. Or, it may, when used with hook type fastening elements, leave just the tips of the hooks exposed. The space filling cover may comprise an elastomeric, a thermoplastic, or a thermoset. It is typically flexible.
[0023] Rather than a cover, there may be, for each segmented fastening region, a gasket that extends fully around the perimeter of the segmented region. The gasket may be a perimeter lip that has been integrally formed with the fastening elements, or that has been applied to the base member separately from the fastening elements. If the fastening elements comprise hook-type elements having free tips, it is beneficial that the gasket comprise a flexible lip that extends away from the base slightly further than the tips. The gasket may comprise a perimeter space filling gasket that covers fastening elements in a perimeter region of the fastening segment.
[0024] Alternatively, according to another preferred embodiment, the fastening segments comprise an internal region that carries the fastening elements and a perimeter region that carries no fastening elements, the gasket comprising a perimeter space filling gasket that covers the perimeter region that carries no fastening elements.
[0025] The base may comprise magnetically attractable material.
[0026] According to still another preferred embodiment, the invention is a method for forming a separable fastener component for use-with a complementary separable fastener component. The method comprises the steps of forming a plurality of fastening segments. Each fastening segment comprises a base member, having a nominal fastening face and a non-fastening face; and carried on the fastening face of the base member, a plurality of fastening elements selected from the group consisting of hook-type and loop-type elements. The method further comprises the step of joining each adjacent pair of fastening segments with a flexible neck that is significantly narrower than the fastening segment.
[0027] The step of forming a plurality of fastening segments comprise the step of providing, on a mold body, a plurality of spaced apart mold cavities shaped to form the fastening segments and between and joining each of the fastening segment mold cavities, a mold cavity shaped to form the flexible neck. The method also includes providing molding material to the mold cavities under sufficient pressure to force the molding material into the mold cavities; and removing the molding material from the cavities after the material has been formed into the fastening segments connected by the necks, to form the fastener component.
[0028] The step of providing molding material may comprise providing molding material to the mold cavities directly through an extrusion nozzle that is closely spaced from the mold cavities.
[0029] The mold body may comprise a mold wheel carrying the mold cavities on a peripheral edge. The step of providing molding material may comprise: providing a second wheel with a peripheral edge closely spaced from the mold wheel so as to form a nip therebetween; and providing molding material to the nip such that molding material is forced into the mold cavities under pressure generated at the nip between the molding wheel and the second wheel.
[0030] According to another preferred embodiment of the invention, the mold body may comprise a plurality of mold plates having similarly curved arcuate edges that are arranged parallel to each other, the mold cavities being formed in the arcuate edges. The mold plates may be circular, or segments of a circle, where the arcuate edges of the segments comprise a portion of a circle, certain of the mold plates being supported so that they are movable in a radial direction relative to the arcuate edge, thereby facilitating removal of a molded fastener component from the mold cavities, the step of removing molding material from the cavities comprising the step of moving radially inward the movable plates so as to release the molded material.
[0031] According to still another embodiment of the invention, the step of providing molding material comprises providing molding material to the mold cavities through an injection mold having at least two parts.
[0032] Still another embodiment of the invention contemplates A molded polymeric body, the body comprising an internal body volume; at least one surface; and a separable fastener component, according to any of the embodiments discussed above, adhered to the surface. The fastener component may be arranged such that segments of the fastener component are angled relative to each other, within a plane defined by the base members of the fastening segments.
[0033] Yet another embodiment of the invention is a method for forming a molded polymeric body as described above, carrying a segmented, separable fastener component as described above. The method comprises the steps of providing a mold, having at least one surface that has a trench therein, where the trench follows a path that has at least two portions that are angled relative to each other in a plane; and, locating in the trench a separable fastener component as described above. The method further includes providing liquid molding material into the mold such that the molding material substantially covers at least the surface of the mold in which the trench resides, and such that molding material contacts a significant portion of the base member of the fastening component, while simultaneously preventing the liquid molding material from contacting the fastening elements. The molding material is allowed to solidify to form the molded polymeric body, whereby the fastening component is secured to the molded body.
[0034] The invention also contemplates, in another embodiment, An apparatus for fabricating a strip of a separable fastening component, as described above. The apparatus comprises a plurality of mold plates, designated a fastener forming zone, having similar arcuate edges. The fastener forming zone further comprises fastening element mold cavities intersecting these edges and one face of the mold plate, the mold cavities being arranged into a plurality of segment forming regions. Circumscribing each of the segment forming regions, is a gasket mold cavity; and between each adjacent pair of segment forming regions, is a hinge forming region. The mold plates are arranged to form a cylindrical mold wheel having a circular surface formed by the arcuate edges of the mold plates such that the segment forming regions are spaced apart circumferentially around the cylindrical surface. The apparatus further comprises an extruder having a die whose surface is disposed close to the cylindrical surface for delivering moldable polymeric material to the mold cavities to form upstanding members and also to the surface to form therewith a polymeric base member strip to which the upstanding members formed in the mold cavities are integrally attached.
[0035] Each of the plates may comprise a circular plate. Alternatively, each of the plates may comprise less than an entire circular-plate, the apparatus further comprising, for each fastener forming zone, a group of the plurality of plates, the members of the group being arranged with the arcuate edges forming the circular cylindrical surface of the mold wheel. The apparatus may further comprise additional pluralities of fastening plates, each of the additional pluralities comprising another fastener forming zone, the additional pluralities being arranged axially along the circular cylinder mold wheel to form side-by side fastener forming zones.
[0036] Still another embodiment of the invention is also an apparatus for fabricating a strip of a separable fastening component, as described above, comprising a plurality of mold plates, designated a fastener forming zone, having similarly curved edges. The mold plates comprise fastening element mold cavities intersecting these edges and one face of the mold plate, the mold cavities being arranged into a plurality of segment forming regions. Circumscribing each of the segment forming regions, a gasket mold cavity; and between each adjacent pair of segment forming regions, is a hinge forming region. The mold plates are arranged to form one component of a multi-piece injection molding assembly having a surface formed by the edges of the mold plates, such that the segment forming regions are spaced apart along the surface. A second component of the injection molding assembly is matable with the surface of the first component. Disposed within at least one of the components of the assembly, are passages for delivering moldable polymeric material to the mold cavities to form upstanding members and also to form therewith a polymeric base member strip to which the upstanding members formed in the mold cavities are integrally attached.
BRIEF DESCRIPTION OF THE FIGURES
[0037] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims and accompanying drawings, where:
[0038] [0038]FIG. 1 is a schematic rendition showing a pair of successive segments of a fastener of the invention, in perspective view, the fastener having an integral, molded perimeter gasket and palm-tree type hook elements;
[0039] [0039]FIG. 2 is a schematic rendition, of a fastener of the invention as shown in FIG. 1, in a plan view;
[0040] [0040]FIG. 3A is a schematic rendition, of a fastener of the invention as shown in FIG. 1, in a side view;
[0041] [0041]FIG. 3B is a portion B of the fastener shown in FIG. 3A, enlarged;
[0042] [0042]FIG. 4A is a schematic rendition of a fastener, as shown in FIG. 2, bent to show its flexibility in one plane, i.e., the plane of the fastener;
[0043] [0043]FIG. 4B is a schematic rendition of a fastener, as shown in FIG. 2, bent to show its flexibility out of the plane of the fastener, where the hinges are bent;
[0044] [0044]FIG. 4C is a schematic rendition of a fastener, as shown in FIG. 2, bent to show its flexibility out of the plane of the fastener, where the hinges are twisted;
[0045] [0045]FIG. 5 is a schematic rendition of a precursor to a fastener of the invention, according to some methods of production, showing an intermediate article of manufacture, before the removal of extra material;
[0046] [0046]FIG. 6 is a schematic rendition of another embodiment of a fastener of the invention, in perspective view, the fastener having a film-like, enveloping cover, with part of the cover broken away from one of the segments;
[0047] [0047]FIG. 7 is a schematic rendition of another embodiment of a fastener of the invention, in perspective view, the fastener having a space filling cover, with part of the cover broken away from one of the segments;
[0048] [0048]FIG. 8 is a schematic rendition of yet another embodiment of a fastener of the invention, in perspective view, the fastener having a space filling cover around the perimeter only;
[0049] [0049]FIG. 9 is a schematic rendition of another embodiment of a fastener of the invention, in perspective view, the fastener having a perimeter gasket of a hot melt adhesive type;
[0050] [0050]FIG. 10 is a schematic rendition in perspective view of any one of the embodiments of the inventions shown above, molded into a body, passing around three orthogonal corners;
[0051] [0051]FIG. 11 is a schematic rendition in perspective view of a complementary fastener component, adhered to the inside of a corner of a flexible fabric cover, for attaching the cover to the molded body shown in FIG. 10;
[0052] [0052]FIG. 12 is a schematic rendition in cross-section of a portion of a fastener, in place in a mold, showing the relative sizes of representative examples of a hooks and a gasket of the invention;
[0053] [0053]FIGS. 13A and 13B are schematic renditions, in top (FIG. 13A) and side (FIG. 13B) views, showing a portion of a fastener of the invention inserted into a mold, before molding material is provided therein;
[0054] [0054]FIG. 13C shows in cross-section a portion of a molded body removed from the mold of FIGS. 13A and 13B, having the fastener attached thereto;
[0055] [0055]FIG. 13D is a schematic rendition in top view, similar to FIG. 13A, showing a portion of a fastener of the invention inserted into a mold having a trench that follows a path having two portions that are angled relative to each other;
[0056] [0056]FIG. 14 is a schematic view of two segment forming regions of a part of a fastener forming apparatus of the invention;
[0057] [0057]FIG. 15 is a schematic view of a part of seven fastener forming zones of a part of a fastener forming apparatus of the invention;
[0058] [0058]FIG. 16 is a schematic view, in partial cross-section, of an apparatus for making a fastener of the invention having an extruder head that presents molding material directly to a mold wheel under pressure;
[0059] [0059]FIG. 17 is a schematic view, in partial cross-section, of an apparatus for making a fastener of the invention having an extruder head that presents molding material into a nip between two rollers, which generate the required molding pressure there between;
[0060] [0060]FIG. 18 is a schematic representation of a two part injection mold for fabricating an embodiment of the invention;
DETAILED DESCRIPTION
[0061] A preferred general embodiment of the invention is shown schematically with reference to FIGS. 1, 2 and 3 A, FIG. 1 being a perspective view of a portion of a product, and FIGS. 2 and 3A being plan and side views thereof. An elongated fastener 10 is made up of a series of adjacent fastening segments 12 , joined by hinges 14 . Each fastening segment 12 includes a base 16 , having a fastening face 18 and a non-fastening face ( 19 , shown in FIG. 3A). The base carries a plurality of fastening elements 20 on the fastening face of the hook and loop type fastener. The fastening elements 20 may be hook type elements or loop type elements. The fastening elements shown in FIG. 1 are double hooked palm-tree shaped hook-type elements, but any other type of hook-type or loop type element could be used. A gasket 22 surrounds each segment. The gasket 22 extends slightly further from the base 16 than does the tip of the fastening elements 20 , as shown in FIG. 12.
[0062] As shown in FIG. 2, the fastener 10 can be a long strip of a large plurality of fastening segments. In a representative embodiment, each segment is twenty-nine mm long, and seventeen mm wide, with the hinges 14 being five mm long. Other sizes are, of course possible. The long strip may be bent at the hinges 14 in many ways. For instance, it can be bent as shown in FIG. 4A, where all of the fastening segments 12 remain essentially in one plane, the plane of the fastener. The minimum bending radius depends predominantly on the relative length of the hinge 14 and the width of the fastening segments. The fastener can also be bent out of the plane of the fastener, around axes that are perpendicular to the long length of the strip of segments, as shown in FIG. 4B. It can also be bent out of the plane of the fastener by twisting a pair of adjacent segments relative to each other around an axis parallel to the long axis, as shown schematically in an end view in FIG. 4C. The fastener can also be bent through any combination of the three modes discussed above.
[0063] For instance, a tape of fifteen of such fastener segments can be made, which tape can then be secured to a foam block 30 as shown in FIG. 10, around three orthogonal edges 34 , 36 and 38 . The fastener bends around the edge 34 in the mode shown in FIG. 4B. It bends on block face 40 in the manner shown in FIG. 4A. No twist is shown in FIG. 10. One or more fabric trim covers can then be attached to the corner of the foam block 30 . Of course, the fastener can also be made to follow a sinuous path 42 on a single face, which includes at least two portions 43 and 45 that are angled relative to each other within the plane of the base 16 of the fastener segments. The possibilities are virtually limitless.
Molded Perimeter Gasket
[0064] In a preferred embodiment, the fastener has an integrally molded perimeter lip gasket 22 , which surrounds the fastening elements 20 to protect them from foam incursion. The means by which the fastening elements 20 are protected is shown schematically with reference to FIGS. 13A, 13B and 13 C. FIG. 13A is a top view of a portion of a mold 50 , having a bottom wall 52 , with a trench 54 formed therein. The trench 54 is sized to accept a fastener strip 10 , shown comprised of a plurality of fastener segments 12 . This figure is not to scale, and shows only two fastener segments in the portion of the mold shown. In actual practice, there will be a much larger plurality of segments in a much larger mold. As shown in FIG. 13B, which is a cross-section of the portion of the mold shown, cut along the jogged lines B-B, the fastener segments 12 are sized so that the free edge of the gasket 22 contacts the bottom of the trench 54 , while the perimeter edges of the fastening face 18 of the base 16 contact the bottom 54 of the mold wall 52 at the edge of the trench. The fastening elements 20 are shorter than the gasket, so they do not touch the bottom of the trench 54 . The fastener is drawn tightly toward the trench bottom by a magnet 58 , which attracts magnetically attractive material that composes the fastener 10 , such as is described in U.S. Pat. No. 5,725,928, identified above. The gasket 22 flexes slightly, as shown enlarged in FIG. 12, and forms a liquid tight seal to protect the fastening elements 20 .
[0065] Liquid foaming material is poured into the mold cavity 60 , such as according to a two component 56 a, 56 b system, as is well known in the art. Some liquid may tend to leak around the edge of the base 16 , into the space 62 between the gasket 22 and the vertical wall 64 of the trench 54 . However, due to the presence of the gasket 22 , and the magnetic force that attracts it to the trench bottom, the liquid can not get through to the place where the fastening elements are. The foaming material then solidifies, and the entire foam block 65 is removed, having the fastener 10 embedded therein. Using the simple trench 54 shown, the fastening elements and the gasket 22 extend outward from the surface 66 of the foam block 65 . There may be small scraps 68 of foam material around the fastening segments, which formed from foam material that leaked into the space 62 . However, these areas do not impede fastening the fastening elements 20 to their mates, for instance, hooks 20 to loops on a fabric trim cover.
[0066] [0066]FIG. 13D is similar to FIG. 13A, and shows schematically, in a top view, a fastener component 10 , made up of fastener segments 12 , connected to each other by hinges 14 , where the fastener component 10 is resting in a trough 55 of a mold 53 , where the trough 55 has two portions 57 and 59 that are angled relative to each other, in the plane of the fastener (i.e., a plane defined roughly by the base 16 of the fastening segment, which is only roughly defined, because the base 16 has a slight radius, as shown in FIG. 3B and discussed elsewhere). The hinge 14 ′ that is between the two segments 12 ′ and 12 ″ is bent so that the fastening component can follow the angle in the trough 55 . Only one angle is shown, for simplicity. However, a large variety of angles and path patterns could be accomplished, limited primarily by the flexibility of the hinge, and the width of the fastening segments.
[0067] Using techniques known in the art, such as ramps, pedestals, etc., it is also possible to have the tips of the fastening elements flush with the surface 66 of the foam block, or submerged, uniformly, or not.
[0068] Rather than a foam part, the fastener can also be incorporated into an unfoamed molded part, either thermoplastic or thermoset.
Manufacture of Fastener
[0069] The molded perimeter gasket, segmented fastener can be made in any suitable way. For instance, the fastener can be made according to the method and apparatus shown generally with reference to U.S. Pat. No. 3,752,619, assigned to Velcro Industries B.V., inventors Menzin, et al. Generally, a large circular cylindrical wheel has hook forming segments distributed around its circumferential edge. The segments are made of ganged together flat plates, with hook forming cavities formed in their edges. When plastic material is forced into the cavities, and thereafter pulled out, hook elements are formed. The hook elements can in some cases be more easily removed, according to the '619 patent, by moving certain of the plate segments radially inward, away from the forming part, thereby freeing the formed hooks. A backing strip may be applied to the formed hooks just downstream of the location where the hooks are formed.
[0070] A portion of a hook forming wheel, for forming two segments, is shown in FIG. 14. The face shown is the circular, cylindrical circumferential surface of a relatively large wheel. The wheel has a fastener forming zone 111 which includes regions 112 for the formation of, for example, more than fifty such segments. Each region is made up of a plurality of parallel plates 113 , some of which have formed therein cavities 116 for the formation of hooks, and some of which may not. There is a region 118 in which no cavities 116 are found, between the regions 112 that form the segments 12 . This is the region where the hinge 14 will be formed. A shallow cavity 114 is provided for the hinge to be formed. A gasket forming cavity 122 is formed entirely around the region 112 where the hooks will be formed. This cavity 122 is flat bottomed, to form a flat edge to the gasket 22 that will be formed. The cavity may be formed by plunge electro-discharge machining into the set of plates after they are ganged together.
[0071] [0071]FIG. 14 shows a two segment portion of one fastener forming zone 111 . Wheels can be fabricated with a plurality of such fastener forming zones spaced axially of the cylinder, across the circumferential surface. FIG. 15 shows a portion of such a wheel with seven fastener forming zones 111 , each of which showing five fastener segment regions 112 for the formation of a fastener segment. It is typically a goal in designing the tooling to make such components to space the forming regions close to each other, to minimize wasted material, reduce the size of the machinery and its power requirements, etc.
[0072] A part as formed on such a tool is shown schematically in FIG. 5. The individual segments 12 can be seen, joined to each other by hinges 14 , as well as the excess material 218 in the regions between the segments 12 . Additional excess material 226 may surround the segments also. This excess material is removed after the strip is removed from the forming wheel.
[0073] As shown in FIG. 3B (which is an enlargement of the portion B of FIG. 3A), as a result of being formed on a circular wheel, having a relatively large radius, R (shown in FIG. 15), the base 16 has a slight curve, concave pointing toward the free fastening element tips (downward in FIG. 3B). The free edge 26 of the gasket seal 22 is, however, flat or straight. This is because the bottom of the cavity 122 in which the gasket is formed, is flat.
[0074] The segmented fastener can be formed in any suitable way, and other ways are possible. It is also possible to form the fastener strip according to a method and with apparatus described in U.S. Pat. No. 4,794,028, also assigned to Velcro Industries B.V., inventor Fischer. According to the '028 process, hook forming plates similar to those described above are used. However, they are not free to move radially. The hooks are shaped in such a way as to allow their removal from the mold without moving of any plates. In one embodiment discussed in the '028 patent, the molten material is applied at a nip between two rollers, one of which has the hook forming cavities on its circumferential edge, the other of which has none, or, perhaps, anchor forming cavities. Very shortly after the nip, the formed strip is stripped from the backing roller, which may or may not include anchor cavities. The strip remains on the hook forming roller for a portion of a circumference, for instance, between about 20°-270° degrees of arc, at which point it is stripped from the hook forming roller. Thus, the formed hooks have time to cool, and are not likely to be deformed as they are pulled from the cavities, particularly given the shape of the cavities.
[0075] The forming roller has the same segment regions 112 , hinge regions 114 and gasket cavities 122 , as does the forming wheel described above in connection with the '619 patent. Typically, in the '028 process, the wheels are formed from full circular plates that are ganged together, whereas in the '619 process, the plates are annular pie shaped sections, to permit some to move radially inward, for the release of the hooks from the mold.
[0076] According to either process, it is possible to make many strips similtaneously, accross the width of the wheel as shown schematically in FIG. 15. For instance, it is typical to make between one and thirty strips or chains at one time. The strips are either individually fabricated (with barriers therebetween on the forming equipment) or are split one from each other after forming.
[0077] The material from which the fastening elements are formed may be presented to the mold in several ways. According to one method, as shown in FIG. 16, an extrusion die 635 of an extruder 646 is placed against the surface of the mold wheel 626 . The figure section is cut at the face of one of the plates 629 , into which mold cavities are cut. The molding material moves through two passages 637 , 638 , under significant pressure and temperature conditions, to insure that the molding material is forced completely into the mold cavities 633 . FIG. 16 shows two extrusion channels: 637 upstream, from which the hooks 621 are formed, and 638 , from which the base member 644 is formed. This extrusion configuration may be used with either the moving plate apparatus disclosed in '619 Menzin patent, or the fixed plate '028 Fischer patent.
[0078] Alternatively, a two roll arrangement can be used, as shown in FIG. 17. A part-forming roll 726 , shown above, in FIG. 17, carries the mold cavities 733 for the fastening elements, such as hooks. A lower roll 716 is closely spaced to the upper roll 726 . An extrusion head 735 supplies a stream E of molding material to the nip 720 between the two rollers 726 and 716 , where pressure is generated to force the molding material into the mold cavities 733 , thereby forming the fastening elements 721 . The formed strip F of fastening elements remains on the forming roll 726 for some portion of its circumference, about 180° of arc as shown, at which point it is stripped away to pass around another, stripping roller 730 .
[0079] In this two or more roll embodiment, the upper, part forming roll 726 may be either the moving plate apparatus disclosed in the Menzin '619 patent, or the fixed plate apparatus disclosed in the Fischer '028 patent.
[0080] The segmented fastener may also be formed using a conventional two (or more) part injection molding apparatus, as shown in FIG. 18. The forming mold 820 has fastener forming zones 811 similar to those on the wheels, described above, which each include five segment forming regions 812 . Four fastener forming zones 811 are shown, although there could be more or fewer. Each region is made of plates 829 , as above, either movable or not, which have the hook forming cavities 833 , the gasket forming cavities 834 and the hinge forming cavities 835 therein. (Only several plates 829 are shown, for clarity. Similarly, hook forming cavities 834 are shown in only two fastener forming zones.) This type of tooling also typically has ejector pins 836 at selected locations around the periphery of the parts to help separate the part from the mold (again, only a few are shown). A mating mold component 839 fits the part forcing component 829 , as is conventional, defining the part by their mutual cavities. Multiple pathways 841 (shown in Phantom) through the mold body 839 are provided, through which the molten material is delivered to the segment forming regions 812 . The network of pathways 841 shown is schematic only. The pressure source for pressurizing the molten material is not shown. Injection molding apparatus may have more than two moving mold bodies 829 and 839 . Only two are shown, again for simplicity.
[0081] After each molding cycle, the formed parts are ejected and shuttled in the direction of the arrows S, such that the next shot fastens itself to the previous shot. This forms a continuous chain that may be taken up on a reel.
Other Types of Seals
[0082] One advantage of the present invention as described above is the near simultaneous fabrication of the fastening segments, fastening elements and perimeter gasket 22 . It is also possible to omit the perimeter gasket 22 or to use, instead, a gasket or a seal or a cover of another type.
[0083] For instance, as shown in FIG. 6, a fastening strip 210 , with individual fastening segments 212 is provided. This fastening strip is identical to that described above, except that it has no gasket 22 around its perimeter. It has segments 212 that are joined by a hinge 14 , which segments and hinge may be formed as described above. The strip has a fastening face 18 , which carries fastening elements 20 , which are shown in FIG. 6 as hooks, but which can be any fastening element described above. Each segment is individually covered by a film-like cover 222 , which seals to the base 216 all around its perimeter, tightly enough to prevent the incursion of foaming material into the region where the fastening elements 20 reside. After the fastening strip has been molded into a foam part, the cover 222 is removed, typically by tearing the seal and ripping off the cover 222 .
[0084] Similar covers are described in the literature, as applied to larger rectangular shaped fastening components. See for instance U.S. Pat. No. 4,693,921 in the name of Billarant et al.
[0085] U.S. Pat. No. 5,766,385, issued on Jun. 16, 1998, in the names of Pollard et al., entitled “Separable Fastener Having Die-Cut Protective Cover with Pull Tab and Method of Making Same” discloses a method of fabricating a fastener with an enveloping cover, of arbitrary shapes. This method can be applied to the segmented covered fastener shown in FIG. 6, and the entire disclosure of the '385 patent is hereby incorporated fully by reference.
[0086] For another example, as shown in FIG. 7, a fastening strip 310 , with individual fastening segments 312 is provided. This fastening strip is identical to that described above, except that it has no gasket 22 around its perimeter. It has segments 312 that are joined by a hinge 14 , which segments and hinge may be formed as described above. The strip has a fastening face 18 , which carries fastening elements 20 , which are shown in FIG. 7 as hooks. Each segment is individually covered by a space filling cover 322 , which intimately surrounds each fastening element 20 and fills the space therebetween, thus preventing the incursion of foaming material into the region where the fastening elements 20 reside, or the adherence of any foam thereto. After the fastening strip has been molded into a foam part, the cover 322 is removed, typically by ripping off the cover 322 .
[0087] Similar covers are described in the literature, as applied to non-segmented fastening components. See for instance U.S. Pat. Nos. 5,286,431 and 5,540,970 in the name of Banfield et al. In the '431 patent, the space filling cover is generally described as fully encapsulating the fastening elements. In the '970 patent, the cover is described as, in some cases, allowing just the tips of the free end of the fastening elements to be exposed, through pinholes 324 in the cover as shown on the right hand segment in FIG. 7. The pinholes may facilitate removal of the cover, due to a reduction in any vacuum that might form. The space filling cover may extend all the way to the fastening surface 18 of the base 16 , or it may be spaced away a small amount, as long as the amount of any foam that does intrude between the foam cover and the base is not so much as to prevent the fastening elements from accomplishing their fastening function.
[0088] For yet another embodiment, as shown in FIG. 8, a fastening strip 410 , with individual fastening segments 412 is provided. This fastening strip is identical to that described above, except that it has no gasket 22 around its perimeter. It has segments 412 that are joined by a hinge 14 , which segments and hinge may be formed as described above. The strip has a fastening face 18 , which carries fastening elements 20 , which are shown in FIG. 8 as hooks. Each segment is individually provided with a perimeter gasket in the form of a space filling cover 422 , which intimately surrounds each fastening element 20 and fills the space therebetween that is positioned in the area upon which the cover is deposited. This cover functions in two modes. First, it serves as a barrier gasket, and prevents any foam from intruding into the central region 426 . Furthermore, it protects those fastening elements in the perimeter that are actually covered by the gasket 422 , in the same manner as the fully covering space filling cover 322 shown in FIG. 7. After the fastening strip has been molded into a foam part, the cover 422 is typically left on the fastener, and the fastening function is performed by the fasteners in the central region. Alternatively, it can be removed, typically by ripping off the cover 422 .
[0089] Similar covers are described in the literature, as applied to non-segmented fastening components. See for instance the above referenced U.S. Pat. No. 5,786,061, inventor Banfield. As with the space filling cover, the perimeter gasket cover may fully encapsulate the fastening elements, or, it may allow just the tips of the free end of the fastening elements to be exposed, through pinholes.
[0090] Another variant of a perimeter gasket, is shown in FIG. 9, having a fastening strip 510 , with individual fastening segments 512 . This fastening strip is almost identical to that described above, except that it has no gasket 22 around its perimeter. It has segments 512 that are joined by a hinge 514 , which segments and hinge may be formed as described above. The strip has a fastening face 518 , which carries fastening elements 520 , which are shown in FIG. 9 as hooks. Each segment is individually provided with a perimeter gasket in the form of a resilient gasket, which does not cover any fastening elements itself, but rather is applied to the base in a perimeter region that does not have any fastening elements. This gasket serves as a barrier gasket, and prevents any foam from intruding into the central region 526 . After the fastening strip has been molded into a foam part, the gasket 522 is typically left on the fastener, and the fastening function is performed by the fasteners in the central region. Alternatively, it can be removed, typically by ripping off the gasket 522 .
[0091] It is also possible to apply a gasket in the form of a film strip, all the way around each segment, similar to that shown in U.S. Pat. Nos. 4,814,036, and 4,726,975, inventor Hatch, identified above. Another type of gasket that can be applied around the gasket is an angled gasket, as shown in U.S. Pat. No. 4,842,916, inventor Ogawa, et al., assigned to Kuraray Company Ltd. Also shown in Ogawa '916 is a felt gasket. A foam gasket seal is shown in U.S. Pat. No. 5,766,723, issued on Jun. 16, 1998, inventor Oborny et al. The disclosures of all of the patents mentioned in this paragraph are hereby incorporated herein by reference.
[0092] The foregoing discussion has most frequently assumed that the segmented fastener will have some means for keeping foaming material from getting into the region of fastening elements, such as a perimeter seal, or a cover. However, the invention is not so limited, and its segmented fasteners alone, without any such barrier, are within the contemplation of the invention. Such fasteners could be used for applications where the fastener is not incorporated into a plastic body. For instance, as shown in FIG. 11, the mating portion 13 of a complementary fastener pair may advantageously be formed from a segmented strip. This allows the fastening component 11 , for instance a loop component that is sewn or otherwise adhered to a flexible fabric seat trim cover 43 , to be smoothly adhered to the seat cover, without buckling, or other restrictions on its location. In general, the seal is not required in that case. The individual segments 13 are connected by hinges 15 , and thus can conform to the shape of the cover. FIG. 11 shows the inside of a three sided corner, in a schematic perspective view.
[0093] Further, if the hooks are chosen to be rather small and close together, no gasket is needed, as the hooks themselves prevent the influx of foam molding material.
[0094] The foregoing discussion should be understood as illustrative and should not be considered to be limiting in any sense. While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the claims.
[0095] The corresponding structures, materials, acts and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or acts for performing the functions in combination with other claimed elements as specifically claimed. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a pull tight seal or cable tie with a predetermined break-away position for removal of a tail. In one example, the invention relates to a pull tight seal including a tag or label for marking devices such as fire extinguishers or other containers.
2. Description of the Related Art
In conventional pull tight seals that are installed on devices, for example, fire extinguishers, the user wraps the pull tight seal around the device, and the user pulls a tail portion through a locking portion of the pull tight that locks barbs via a ratchet effect. The tail cannot be pulled backward through the lock due to the shape of the barbs, which allow motion through the lock in only one direction. A similar arrangement is provided for so-called “cable ties,” and the term “tie” will be used to identify a group including both pull tight seals and cable ties.
In conventional ties, after fastening, part of the tail often protrudes from the end of the locking portion and can interfere with inspection of the tie after installation. Additionally, this unwieldy portion of the tail can get caught in other devices or seals when moving or using the device. This protruding portion of the tail is particularly problematic when the tie is installed in fire a extinguisher, which is often used in emergency situations.
SUMMARY OF THE INVENTION
Accordingly, one aspect of the present invention provides a flexible tie including a head having a first cross-sectional geometry and a tail extending from the head in a longitudinal direction and having a second cross-sectional geometry different from the first cross-sectional geometry. The tie includes a lock disposed on the head and including a passage configured to receive the tail and a plurality of barbs disposed on the tail and configured to pass through the passage in the lock in a first direction, and configured to be restricted from retreating through the passage in a second direction opposite to the first direction. The tie also includes a tail break-point disposed on the tail and including a first cross-sectional area, as viewed along the longitudinal direction, smaller than any other cross-sectional area of the tail as viewed along the longitudinal direction. In some configurations, the tie includes a visual indicator in the head.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages of the invention will become more apparent and more readily appreciated from the following detailed description of the exemplary embodiments of the invention taken in conjunction with the accompanying drawings where:
FIG. 1 is a top view of one example of the inventive tie;
FIG. 2 is a front view of the tie shown in FIG. 1 ;
FIG. 3 is a bottom view of the tie shown in FIG. 1 ;
FIG. 4 is a top view of another example of the inventive tie;
FIG. 5 is a front view of the tie shown in FIG. 4 ;
FIG. 6 is a bottom view of the tie shown in FIG. 4 ;
FIG. 7 is a top view of one example of the inventive tie;
FIG. 8 is a front view of the tie shown in FIG. 7 ;
FIG. 9 is a bottom view of the tie shown in FIG. 7 ;
FIG. 10 is a top view of another example of the inventive tie;
FIG. 11 is a front view of the tie shown in FIG. 10 ;
FIG. 12 is a front view of the tie shown in FIG. 10 ; and
FIG. 13 is a view of a conventional tie.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described hereinafter with reference to the accompanying drawings. In the following description, the constituent elements having substantially the same function and arrangement are denoted by the same reference numerals, and repetitive descriptions will be made only when necessary.
With reference to FIGS. 1-3 , one example of the inventive tie 1 is shown in which a head 5 including a front side 6 and a back side 7 is connected to a tail 60 that has at least one different cross-sectional geometry from the cross-sectional geometry of the head 5 . At least one of the front side 6 and back side 7 of the head 5 is typically configured to display or receive an informational visual indicator such as a writing, stamping, or sticker. In the example shown, a neck 65 occupies a portion of the tail 60 and serves to strengthen the connection between the head 5 and the tail 60 . For example, as measured in the radial direction, the neck 65 can have larger dimensions than the tail 60 . In some examples, the tail does not include the neck 65 . The tie 1 can be formed of any of a variety of flexible materials, but plastics such as polypropylene are typically used. In some embodiments, the tie 1 is color-coded for a particular use. As would be familiar to a person of ordinary skill in the art, the tail 60 extends away from the head 5 in a longitudinal direction (to the right in FIG. 1 ) and is configured to bend around an object in order to be secured to the object when the tail is in a locked position.
The head 5 further includes a lock protrusion 75 . The lock protrusion 75 includes a lock 70 and typically includes one or more tab 72 disposed on or near the lock 70 . As shown in FIGS. 1-3 , the lock protrusion 75 may be generally conical in shape. However, other shapes are possible.
As further shown in FIGS. 1-3 a series of barbs 10 are disposed on the tail 60 . The barbs 10 are separated from each other by a series of core portions 20 . As shown in FIGS. 1-3 , the barbs 10 may be conical or shaped as a truncated cone. In one embodiment, the barbs 10 have a maximum (major) diameter of 0.085 inches and a cone angle of 15 degrees. In one example, there is a 0.07 inch distance from a perpendicular face corresponding to the major diameter of one of the barbs 10 and the conical portion of the next closest of the barbs 10 . As the barbs 10 are made to slide into the lock 70 , the conical or frustoconical shape assists in a ratcheting effect in which the barbs 10 pass through the lock 70 and are locked in place by the tab 72 so as to resist passing through the lock 70 in a direction opposite to that of entry. The core portions 20 typically have a major (outermost) diameter of approximately 0.06 inches, where “approximately” means plus or minus 0.01 inch. In some applications, the barbs 10 and/or core portions 20 are not round, but are instead oval, polygonal, or some other shape. In these cases, the minimum cross-sectional dimension is preferably 0.06 inches. However, with all of the above-noted dimensions, variations are available depending upon the need of the user.
As shown in FIGS. 1-3 , an optional intermediate grip 30 may be disposed on the tail 60 and serves to allow a user to comfortably grip the tail 60 without touching the barbs 10 . In some embodiments, the intermediate grip 30 is omitted in order to simplify manufacture. In some embodiments, the intermediate grip 30 has a flattened cross-section ( FIGS. 10-12 ) in order to allow a strong, but still flexible tie 1 . In other words, the flattened intermediate grip 30 allows a preferred direction of bending, which can make inspection of the front side 6 and back side 7 of the head 5 easier. The intermediate grip 30 may be incorporated into any of the embodiments of the present invention disclosed herein.
FIGS. 1-3 also depict an optional stopper 40 , which may be used to stop movement of the tail 60 at a predetermined position and/or to prevent over-tightening. In some instances, it is preferable not to tighten the tail 60 to the extent that the loop formed by the tail 60 after the tail 60 passes through the lock 70 grabs the object around which the tail 60 is wrapped. For example, if the tie 1 is used to identify an inspection date for a fire extinguisher, it is generally preferable to allow easy inspection of the front side 6 and back side 7 by providing a loose connection between the tail 60 and the connection loop or orifice on the fire extinguisher. The loose connection allows the front side 6 and back side 7 to be examined without putting strain on the tail 60 , and therefore assists in allowing the tail 60 to avoid wear and tear while it is attached to the fire extinguisher. FIGS. 4-5 depict examples without the optional stopper 40 or intermediate grip 30 . FIGS. 7-9 depict examples without the stopper 40 and with grips 63 disposed on the disposable portion 62 . The grips 63 typically have a diameter smaller than the diameter of the barbs 10 in order to allow smooth passage of the tail 60 through the lock 70 . The grip 63 may be incorporated into any of the embodiments of the invention disclosed herein.
If the optional stopper 40 is disposed on the tail 60 , then the barbs 10 disposed between the head 5 and the stopper 40 will typically be unused inasmuch as these barbs will not pass through the lock 70 during attachment. FIGS. 1-3 depict barbs between the stopper 40 and head 5 in order to show that the same tail 60 may be made to include or not include the stopper 40 depending on the needs of the user.
The barbs 10 disposed between the stopper 40 and the end of the tie 1 opposite the head 5 are used to secure the tie 1 in the lock 70 . As shown in FIGS. 1-3 , a predetermined break-away 50 is disposed on the tail 60 . The predetermined break-away 50 is typically the physically weakest point on the tail 60 and allows a user to cleanly snap off the disposable portion 62 after the tail 60 is looped through the lock 70 and the item to which the tie 1 is attached. Preferably, the tensile force required to break the tail via the predetermined break-away 50 , as measured by pulling straight down the length of the tie 1 , is between four and eight pounds, while the force required to break the tail 60 without the predetermined break-away 50 is between seven and eleven pounds. Preferably, the force required to break the tail 60 at the predetermined break-away 50 is less than the force required to break the tail 60 without the predetermined break-away 50 . Thus, the predetermined break-away 50 provides a convenient predetermined failure section allowing the user to know in advance of breaking exactly where the tail 60 of the tie 1 will break once sufficient tensile force is applied to the tie 1 .
Preferably, the ratio of diameter of the predetermined break-away 50 to the diameter or largest dimension of the core portions 20 is 2/3 in order to allow a significant difference in tensile strength between these two components and to ensure that the predetermined break-away 50 breaks before any of the core portions 20 or other parts of the tail 60 break. Preferably, the outermost dimension or diameter of the predetermined break-away 50 is approximately 0.04 inches. Additionally, it is preferable that the predetermined break-away 50 be approximately 0.10 inches long in order to provide a visible indication of the break point to a user prior to breaking. It should be noted that in some embodiments, the cross-section of the tail is not circular. Similarly, in some embodiments, the cross-section of the predetermined break-away 50 is not circular. In examples where the cross-section of one or both of the tail 60 and predetermined break-away 50 is not circular, it is preferred that similar breakage characteristics are provided by the tail 60 and predetermined break-away 50 to those noted above regarding the 2/3 diameter. In other words, the ratio of cross-sectional area of the tail 60 , in the direction the tail 60 extends from the head 5 , is larger than the cross-sectional area of the predetermined break-away 50 . Preferably, when one or more of the predetermined break-away 50 and tail 60 is non-circular, the ratio of the cross-sectional area of the predetermined break-away 50 to the minimum cross-sectional area of the tail 60 other than the predetermined break-away 50 is 4/9, just as it would be for circular cross-sections when the ratio of the diameters is 2/3.
As further shown in FIGS. 1-3 , the tail 60 may include a disposable portion 62 , which can be gripped by the user and inserted into the lock 70 . In other embodiments, the barbs 10 extend across the area occupied by the disposable portion 62 in FIGS. 1-3 .
In practice, the user wraps the tie 1 around an object to be secured or tagged, and the user pulls the tail 60 through the lock 70 until at least one of the barbs 10 are locked by the tab 72 . Due to the shape of the barbs 10 , the barbs 10 cannot be easily pulled back through the lock 70 , and the tie 1 is permanently wrapped around the object until the tie 1 is cut or otherwise damaged. If the optional stopper 40 is present, the user will typically pull the tail 60 until it “bottoms out” on the stopper 40 . At this point, or when the tie grips the object if no stopper is present, the user pulls with greater force, and the tail 60 will break at the predetermined break-away 50 while leaving no portion, or only a short stub, of the tail 60 protruding from the lock 70 . Thus, the predetermined break-away 50 allows a clean break to be formed without an unwieldy portion of the tail 60 dangling from the lock 70 , which could get caught or tangled on other objects. This clean break is particularly helpful when tagging fire extinguishers as these are often handled during emergency situations.
Although only certain embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiment without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention. | 4y
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BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
This invention relates generally to an apparatus and method for transporting mobility devices and, more specifically, to an apparatus and method for transporting mobility devices on the back of a vehicle in a secure and convenient manner.
BACKGROUND OF THE INVENTION
In recent years, a variety of electric scooters, power wheelchairs, and other mobility devices have been developed. The purpose of these devices is to provide mobility-restricted individuals with greater mobility and freedom. One popular chair is the JAZZY®, manufactured in several models by Pride Health Care. There are currently several apparatuses which have been developed to lift and transport mobility devices, including apparatuses which are designed to be mounted on the rear of a vehicle.
Generally, these prior art apparatuses provide a platform, upon which the mobility device is loaded, with the device's drive wheels resting on top of the platform. Where the device is a power chair, it is generally manually secured to the platform with straps or ties of some kind. This method of securing the power chair can be demanding physically, and is not entirely secure.
Therefore, a need existed for an apparatus and method for efficiently loading and transporting mobility devices. The improved apparatus and method must allow the user of the mobility device or the user's companion to readily drive the device onto the apparatus, and must automatically secure the device into position without requiring the use of straps or other manual techniques.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved automobile-mounted apparatus for transporting mobility devices and method therefor.
It is another object of the present invention to provide an apparatus and method for transporting mobility devices that will automatically center and retain the main drive wheels of the device for transport.
It is a further object of the present invention to provide an apparatus and method for transporting mobility devices that will automatically secure the device for transport.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with one embodiment of the present invention, an apparatus for transporting mobility devices is disclosed. The apparatus is comprised of a mobility device having two relatively large wheels; a support platform for the mobility device comprising: loading means for permitting the mobility device to be located on the support platform; first and second wheel wells located between the loading means, the first and second wheel wells each having a width greater than a width of each of the relatively large wheels; means located within each of the first and second wheel wells for substantially centering the relatively large wheels; and retaining means for retaining a bottom portion of the mobility device to the support platform; lifting means attached to the support platform proximate the first wheel well for lifting the support platform; and means for attaching the lifting means to a vehicle.
In accordance with another embodiment of the present invention, an apparatus for transporting mobility devices is disclosed. The apparatus is comprised of a mobility device having two relatively large wheels and at least two relatively small safety wheels; a support platform for the mobility device comprising: loading means for permitting the mobility device to be located on the support platform the loading means comprising: a first pair of ramp members substantially aligned with the first and second wheel wells on a first side of the support platform wherein each of the ramp members is aligned with one of the two relatively large wheels and one of the at least two relatively small wheels; a second pair of ramp members substantially aligned with the first and second wheel wells on a second side of the support platform wherein each of the ramp members is aligned with one of the two relatively large wheels and one of the at least two relatively small wheels; and path means joining the first and second pairs of ramp members for permitting the relatively small wheels to pass adjacent the first and second wheel wells during loading and unloading of the mobility device; first and second rectangle-shaped wheel wells located between the loading means, the first wheel well having a width of between about three inches and about three and one-half inches and the second wheel well having a width of between about three and three-quarters inches and about four and one-quarter inches; means located within each of the first and second wheel wells for substantially centering the drive wheels; the centering means comprising a pair of substantially stirrup-shaped members rotatably coupled to the support platform and located proximate short sides of the wheel wells and spring means for maintaining the stirrup-shaped members in a substantially horizontal position when the relatively large wheels are not present in the wheel wells and to maintain the stirrup-shaped members in contact with the relatively large wheels when the relatively large wheels are present in the wheel wells; retaining means for retaining a bottom portion of the mobility device to the support platform; the retaining means comprising at least one substantially L-shaped member rotatably coupled to the support platform; the substantially L-shaped member dimensioned to retain a bottom portion of the mobility device; and rotation means coupled to the at least one substantially L-shaped member for rotating the L-shaped member from a position substantially parallel to the support platform to a substantially ninety degree angle relative to the support platform wherein the L-shaped member retains the bottom portion of the mobility device; a plurality of eyelets; lifting means attached to the support platform proximate the first wheel well for lifting the support platform; means for automatically rotating the support platform toward the lifting means when the support platform is raised without a mobility device being located thereon; and means for attaching the lifting means to a vehicle.
In accordance with still another embodiment of the present invention, an improved method for transporting mobility devices is disclosed. The method comprises the steps of: providing a mobility device having two relatively large wheels; providing a support platform for the mobility device comprising: loading means for permitting the mobility device to be located on the support platform; first and second wheel wells located between the loading means, the first and second wheel wells each having a width greater than a width of each of the relatively large wheels; means located within each of the first and second wheel wells for substantially centering the relatively large wheels; and retaining means for retaining a bottom portion of the mobility device to the support platform; providing lifting means attached to the support platform proximate the first wheel well for lifting the support platform; and providing means for attaching the lifting means to a vehicle.
The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more particular, description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the preferred embodiment of the mobility device transporting apparatus of the present invention, shown coupled to a vehicle and with a mobility device in position to be loaded onto the support platform of the apparatus.
FIG. 2 is a top view of the mobility device transporting apparatus of the present invention.
FIG. 3 is a side view of the lifting apparatus portion of the transporting apparatus of FIG. 2 taken along line 3--3.
FIG. 4 is a side view of the lifting apparatus portion of the transporting apparatus of FIG. 2 taken along line 4--4.
FIG. 5 is a front view of the transporting apparatus of the present invention, shown coupled to a vehicle and with a mobility device loaded onto the support platform of the apparatus.
FIG. 6 is a view of the lifting apparatus portion of the transporting apparatus of the present invention taken along line 66 of FIG. 4.
FIG. 7 is a cut-away view of the latching mechanism of the present invention.
FIG. 8 is a cross-sectional view of a portion of the latching mechanism of the present invention taken along line 8--8 of FIG. 7.
FIG. 9 is a perspective view of one embodiment of an adapter for the transporting apparatus of the present invention.
FIG. 10 is a side cross-sectional view of the lifting apparatus portion of the transporting apparatus of FIG. 6 taken along line 10--10.
FIG. 11 is a perspective view of another embodiment of an adapter for the transporting apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the embodiment of FIGS. 1 and 2, reference number 10 refers generally to the transport apparatus of this invention. Reference number 12 refers generally to the platform of the present invention, which platform receives a mobility device 14 as shown in FIGS. 1 and 5. Reference number 16 refers generally to the lifting apparatus of the present invention. As shown in FIGS. 1 and 5, the mobility device 14 comprises two drive wheels 18 (only one of which is shown), two support wheels 20A positioned to the rear of the drive wheels 18, and two anti-tip wheels 20B positioned to the front of the drive wheels 18.
Referring specifically to FIGS. 1 and 2, the platform 12 comprises a pair of ramps 22 on a first side A of the platform 12, and a pair of ramps 22 on a second side B of the platform 12, each of which ramps 22 is wide enough to accommodate the drive wheel 18 and support wheels 20A that are in alignment with the respective ramp 22. The ramps 22 permit a mobility device 14 to drive onto the platform 12 from side A and to drive off of the platform 12 from either side A or side B.
Located between each opposing pair of support ramps 22 is a first drive wheel well 24 and a second drive wheel well 25. Adjacent each drive wheel well 24 and 25 and parallel thereto, on the side nearest the center of the platform 12, is a support wheel path 26. The support wheel path 26 allows the support wheels 20A to travel over the platform 12 during loading and unloading. Preferably, when the transport apparatus 10 of the present invention is being used with a JAZZY® power chair, wheel well 24 should have a width of approximately three and one-quarter inches, and wheel well 25 should have a width of about four inches, to allow the platform to lower fully without binding on the drive wheels 18 as they touch the ground. In particular, by making wheel well 25 wider than wheel well 24, it is possible to reduce, if not eliminate, the tendency of the drive wheel 18 located in the wheel well 25 to rub on the inside of the wheel well 25 during lowering of the platform 12. While the width of the wheel wells 24 and 25 can be altered without departing from the spirit or scope of the invention, a sizing of the wheel wells 24 and 25 that is too large may result in the mobility device 14 swivelling within the wheel wells 24 and 25, preventing the latching apparatus (described below) from functioning properly.
Located at each of the short sides of the wheel wells 24 and 25 are centering devices 28, which centering devices 28 are substantially stirrup-shaped. The centering devices 28 rotate about shafts 30, with such rotation being limited by torsion springs 32 which are attached about shafts 30 and which connect a side member of each center device 28 to the nearest short side of the respective wheel wells 24 and 25, as shown in FIG. 2. The torsion springs cause the centering devices 28 to maintain a position that is substantially parallel to the support wheel paths 26, and thus prevent the centering devices 28 from hanging below the plane of the platform 12 when the transport apparatus 10 is not in use. When a mobility device 14 is located on the platform 12 so that the drive wheels 18 are located in the wheel wells 24 and 25, the drive wheels 18 rest on the centering devices 28, and the centering devices 28 substantially center the drive wheels 18 within their respective wheel wells. Additionally, the centering devices 28 provide an easier exit and entrance of the mobility device 14 by providing a ramp effect and thereby limiting the amount of drop when the drive wheels 18 enter the wheel wells 24 and 25.
Referring specifically to FIG. 7, the automatic latching apparatus 34 of the transport apparatus 10 is shown. The latching apparatus 34 comprises a first shaft 36, preferably having a diameter of three-fourths of one inch, and a second shaft 38 substantially parallel to the first shaft 36, and preferably having a diameter of one-half of one inch. The first shaft 36 is rotatably mounted at both ends to the platform 12, as shown in FIG. 2. The second shaft 38 is rotatably mounted at one end to the platform 12, as shown in FIG. 2, and passes through openings 39 in the platform 12. Proximate both ends of the second shaft 38 are L-shaped latches 40, which latches 40 can be made of flat stock, metal rods, or any other appropriate material. A cable 42 is wound around each of the first shaft 36 and the second shaft 38. One end of the cable 42 is connected to the first shaft 36, while the second end of the cable 42 is connected to a spring 44, which spring 44 is attached to a wall 45 that abuts the support ramp 22 located on side A of the platform 12 as shown in FIG. 2. The spring 44 provides tension during the automatic latching and unlatching of the mobility device 14.
Referring specifically to FIGS. 7 and 8, located along first shaft 36 is a latch engaging mechanism 46. The latch engaging mechanism 46 is substantially L-shaped, with a base member 48 comprising a pair of opposing rectangle-shaped members, an arm member 50 which is rotatably coupled to the base member 48, and a wheel 52 which is rotatably coupled to the arm member 50. Adjustably connected at substantially a ninety degree angle to arm member 50 distal the wheel 52 is a push rod 54. The end of the push rod 54 that is adjustably connected to the arm 50 is threaded, and the push rod 54 is adjustably connected to the arm 50 with a nut 55. The length of the push rod 54 below the arm 50 determines the amount of travel of the latches 40. That length can be adjusted with the nut 55. The second end of the push rod 54 is rotatably connected to a substantially Y-shaped member 56, which extends from and is fixedly connected to the first shaft 36, and which Y-shaped member 56 is substantially parallel to the arm member 50.
Referring to FIGS. 1 and 5, the lifting apparatus 16 is capable of lowering the platform 12 to a position adjacent the ground, so that a mobility device 14 may be safely driven onto or off of the platform 12. The lifting apparatus 16 is also capable of lifting the platform 12, with a mobility device 14 located thereon, until the platform 12 is at a height above the ground that is safe for travel. As shown in FIGS. 3 and 4, if no mobility device 14 is located on the platform 12, then the transport apparatus 10 will "fold" by causing the platform 12 to automatically move toward the lifting apparatus 16, until the platform 12 and the lifting apparatus 16 are nearly in contact with each other. Prior art machines have the capability of automatically "folding" in this manner.
When a mobility device 14 is located on the platform 12, the platform 12 will remain at substantially a ninety degree angle relative to the lifting apparatus 16 while the platform 12 is lifted to a height that is safe for travel, as shown in FIG. 1. As shown in FIGS. 7 and 8, as the platform 12 is being lifted, the wheel 52 will contact an angled face 58, which angled face 58 is located at one end of a body 60, which is attached at a second end at substantially a ninety degree angle relative to the lifting apparatus 16. As the wheel 52 moves upward along the angled face 58, the arm member 50 will rotate toward the push rod 54, causing the first shaft 36 to turn. That turning, which is communicated through cable 42 to the second shaft 38, causes the second shaft 38 and thus the L-shaped members 40 to turn in a clockwise direction. The L-shaped members 40 will continue to turn until the short ends of the L-shaped members 40 pass over a portion of the undercarriage (not shown) of the mobility device 14, thereby retaining the mobility device 14 in position. The L-shaped members 40 may not actually contact the undercarriage of the mobility device 14; rather, the short ends are positioned over the undercarriage so as to prevent it from lifting up from the platform 12 during travel.
A plurality of eyelets 62 may be attached to the platform 12 as shown in FIG. 1, to provide fastening locations for bungee cords or other similar devices, used to further secure the mobility device 14 to the platform 12 if desired.
Referring to FIGS. 9 and 11, certain models of mobility devices 14 lack an undercarriage portion positioned so that the mobility device 14 may be retained with one or more of the L-shaped members 40. For example, one model of the JAZZY® power chair has a leg rest feature, the creation of which results in the omission of a portion of the undercarriage that would otherwise be positioned under one of more of the L-shaped members 40. Referring first to FIG. 9, reference FIG. 100 refers to a portion of the undercarriage of a mobility device 14 of this particular type. It is necessary to provide an extension perpendicularly from the undercarriage portion 100 so that this particular mobility device 14 may be retained by one or more of the L-shaped members 14. The extension 110 comprises a tube member 120, an L-shaped lip portion 130, and an L-shaped removable plate 140. The extension 110 is secured in position by placing the L-shaped lip portion 130 over the undercarriage portion 100 as shown in FIG. 9, by placing the L-shaped removable plate under the undercarriage portion 100 so as to be in line with the L-shaped lip portion 130, and to secure the L-shaped plate 140 relative to the tube member 120 and the undercarriage portion 100 with a screw 150 which passes through an opening 160 in the L-shaped plate 140.
Referring now to FIG. 11, shown is an undercarriage portion 200 of another type of mobility device 14. An example of a mobility device 14 having an undercarriage portion 200 of this dimension is a JAZZY® power chair having a remote control feature. The undercarriage portion 200 has a projection 210, into which an extension 220 of appropriate dimension may be inserted. The extension 220 may be secured into position using a screw 230 that is inserted through an opening 240 in the in the projection 210.
Referring now to FIGS. 1, 3, 4, 6 and 10, the locking apparatus 300 of the present invention is shown. While other transport apparatuses are capable of folding automatically when a mobility device is not present on the platform--a feature of the present invention as well--the apparatus of the present invention also has the capability of mechanically locking the platform 12 in an up position proximate the lifting apparatus 16. The locking apparatus 300 comprises a piston 310, which is coupled to an extension 320, which extension 320 is slidably retained within a housing 330. Rotatably coupled to housing 330 is an outer housing 340, which rotates about bolt 350. As shown in FIG. 10, located in an upper portion of the outer housing 340 is a first roller 360 located nearer the side that is distal the bolt 350, and slightly below the roller 360 and located nearer the side that is proximate the bolt 350 is a second roller 370. Slidably retained to the outer housing 340 is a locking leg 380, which is capable of sliding in a vertical direction relative to the outer housing 340 along bolts 390, which are retained within grooves 400. The housing 330 is rotatably coupled to the lifting apparatus 16 along bolt 410.
At a distal end of the locking leg 380, there is located a projection 420. At the proximate end of the locking leg 380, there is a plate 430 having a substantially U-shaped opening 440 therein. Attached at a proximate end of the housing 330 is a substantially rectangular member 450, which member 450 has located thereon a bolt 460 and a bolt 470. Bolt 470 is substantially parallel to the roller 370, while the bolt 460 is substantially parallel to the roller 360. A pair of springs 480 are coupled on both sides to the exposed ends of bolt 460 and roller 360.
The locking apparatus 300 operates in the following manner. When the platform 12 is lifted by the lifting apparatus 16, piston 310 will travel in an upwards direction. If a mobility device is not present on the platform 12, the platform 12 will ascend in a parallel manner while the springs 480 maintain the member 450 and the outer housing 340 in an adjacent position. As the platform 12 proceeds higher, a bolt 490 (see FIG. 1) on the platform 12 will contact the projection 420. This will cause the locking leg 380 to travel upward, until the bolt 470 enters the U-shaped opening 440 as shown in FIG. 3. At this point, the platform 12 will be locked in position relative to the lifting apparatus 16.
If a mobility device 14 is present on the platform 12, the weight of the mobility device 14 will cause the extension 320 to force apart the springs 480, causing the outer housing 340 to rotate away from the member 450 along bolt 350. This rotation will prevent the bolt 470 from entering the U-shaped opening 440 and will prevent the plate 430 from contacting the bolt 470, as shown in FIG. 10.
Operation of the Invention
The transport apparatus 10 of the current invention may be used to lift and transport a mobility device 14. To lift a mobility device 14, the user will first wheel or drive the mobility device 14 onto the ramps 22 from side A of the platform 12. The anti-tip wheels 20B and the drive wheels 18 will first ascend the ramps 22, and the drive wheels 18 will enter the wheel wells 24 and 25, coming to rest on the centering devices 28. The anti-tip wheels 20B will pass next to the wheel wells 24 and 25, along support wheel paths 26, and down the opposing ramps 22. The user will stop the mobility device 14 when the drive wheels 18 are each in their respective wheel wells 24 and 25, resting on the centering devices 28.
The user will next activate the lifting apparatus 16 of the present invention, causing the L-shaped members 40 to secure the mobility device 14 to the platform 12, as shown in FIGS. 7 and 8 and as described above. When the platform 12 has been raised to a secure position for travel, the lifting apparatus 16 is turned off. The user may then, optionally, further secure the mobility device 14 to the eyelets 62 with bungee cords, cables, or like devices.
When the user is prepared to unload the mobility device 14, the process is reversed. If bungee cords, cables or like devices have been used to further secure the mobility device 14 to the platform 12, those devices are removed. The lifting apparatus 16 lowers the platform 12 until the platform 12 reaches the ground. As the platform 12 is lowered, the L-shaped members 40 rotate in the opposite direction, until they are fully open and are no longer in position to prevent the movement of the mobility device 14 from the platform 12. The drive wheels 18 will settle on the ground, allowing the platform 12 to continue to descend until it also rests on the ground. At this point, the mobility device 14 may be driven off of the platform 12 from Side B or backed off from Side A.
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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FIELD OF THE INVENTION
The present invention relates to a new method for purging oxygen from a sealed container interior and a purge substance for accomplishing it. The present application more particularly discloses a process for the decomposition of hydrocarbon containing material exploiting the method described herein.
BACKGROUND OF THE INVENTION
The thermal decomposition of hydrocarbon containing material (i.e., pyrolysis) has been widely discussed. Both continuous and batch processes have been proposed and most of the processes described in the literature require an oxygen-free environment due to the high temperatures at which the process is performed.
Prior art, such as U.S. Pat. No. 4,301,750 (Fio Rito; November, 1981), the entire content of which is incorporated herein by reference, discuss continuous processes performed under a substantially oxygen-free environment. The main problem with such processes and apparatus is that seals are never totally reliable. Indeed, since continuous process requires continuous feed of material from the outside into the reactor, specific dynamic seals must be provided. Considering the important consequences of outside air leakage into the reactor chamber, it is considered an unacceptable risk to undertake thermal decomposition operations by use of a continuous process. Batch processes and apparatus such as, for example, the one disclosed in U.S. Pat. No. 5,821,396 (Bouzianne, R.; October, 1998) and U.S. Pat. No. 5,820,736 (Bouzianne, R. and R., Michaud; October, 1998), the entire content of which are incorporated herein by reference, are preferably used.
Processes for the thermal decomposition of material performed at elevated temperature, either continuous or batch processes require a substantially oxygen-free (i.e., anoxic) environment inside the reactor chamber (i.e., drum). The anoxic environment is essential since an oxygen (O 2 ) leakage inside the apparatus (e.g., drum, reactor chamber) is likely to result in a violent explosion. This risk can be especially appreciated when considering that the thermal decomposition and cracking reactions are usually occurring in the temperature range of, for example, between 225° C. and 510° C. Thus, air (containing oxygen), has to be removed from the inside of the reactor chamber. Many apparatus and process rely on the use of a vacuum pump(s) to remove air from inside the reactor chamber. However, even if a complete vacuum inside the apparatus (e.g., drum, reactor chamber) is usually not a prerequisite, a substantially oxygen-free environment is required.
As it is the case for many prior art apparatus, the sealed reactor chamber of the batch process disclosed in U.S. Pat. No. 5,820,736 (Bouzianne, R. and R., Michaud; October, 1998) requires an almost complete vacuum to be created inside the drum reactor chamber to remove oxygen from therein. For this purpose, expensive vacuum pumps and seals are needed. Thus, creating a vacuum inside a reactor chamber is an expensive step.
It would be advantageous to have an improved method of (for) removing oxygen from a sealed closed space. Such improved method may be performed by way of a substance purge using a purge substance and more particularly an oxyphilic solution as described herein. The batch process described herein would then be advantageously achieved without the use of expensive vacuum pump and seals. Instead, a purge substance such as, for example, an oxyphilic solution may be loaded into a reactor and following sealing and heating of the reactor's interior to a predetermined temperature, the purge substance may allow the oxygen to be driven out of the interior of the container through a gas evacuation component. Unless otherwise indicated, percentages (%) are expressed on a basis of volume/volume (v/v).
SUMMARY OF THE INVENTION
In a first aspect, the present invention provides a method for purging or expelling oxygen (i.e., performing a substance purge) from a sealed container interior, the container (e.g., reactor) being associated with a gas evacuation component, said method comprising heating the interior of the container containing a purge substance to a predetermined temperature to induce the purge substance to drive oxygen out of the interior of the container through said gas evacuation component.
In accordance with the present invention, the method of purging of oxygen (i.e., substance purge) may be performed by using a purge substance which may be selected from the group consisting of solid and liquid purge substance and mixture thereof, (e.g., water or an oxyphilic solution as described herein). It is to be understood herein, that a “purge substance” may also be any liquid (e.g., water) or solid that may be transformed into a gas (i.e., vapor) under suitable conditions (e.g., following heating) for displacing oxygen from a sealed container through a (gas) evacuation component. The amount of said purge substance, should be sufficient enough to produce a volume of gas (vapor) that will allow the generation of a substantially oxygen-free environment in a container (reactor) of a desired dimension.
Also in accordance with the present invention, the predetermined temperature may correspond, for example, to a temperature at which said purge substance becomes a gas.
In a further aspect, the present invention relates to a batch process for the thermal decomposition of a hydrocarbon containing material in a sealed reactor interior, said reactor being provided with a gas evacuation component, said process comprising the steps of:
a) loading the hydrocarbon containing material into and sealing the reactor; b) purging or expelling oxygen from said reactor; and c) heating said reactor to a predetermined temperature so as to obtain decomposition products,
the improvement wherein the purging step includes loading the reactor with a purge substance prior to sealing the reactor and heating the interior of the sealed reactor to a first predetermined temperature to induce the purge substance to drive oxygen out of the interior of the container through said gas evacuation component.
In accordance with the present invention, the process may include recovering said decomposition product, e.g., gas, condensed vapor (containing water and/or alcohol and/or hydrocarbons having 6 or 7 carbon atoms and mixtures thereof), oil, carbon black and steel.
In a further particular aspect, the present invention provides a method for purging or expelling oxygen (for example, performing a substance purge) from a sealed container (e.g., a batch reactor) interior, the container being associated with a gas evacuation component, said method comprising heating the interior of the container containing an oxyphilic solution to a predetermined temperature to induce the oxyphilic solution to drive oxygen out of the interior of the container through said gas evacuation component.
In accordance with the, present invention, the method described herein may further comprise the step of collecting gas that are evacuated through said gas evacuation component.
In accordance with the present invention the predetermined temperature may be comprised for example between 100° C. and 225° C., when the method described herein is used in the thermal decomposition of tires.
In an additional aspect, the present invention relates to an improved batch process for the thermal decomposition of a hydrocarbon containing material in a sealed reactor interior, said reactor being provided with a gas evacuation component, said process comprising the steps of:
a) loading the hydrocarbon containing material into and sealing the reactor; b) purging or expelling oxygen from said reactor; and c) heating said reactor to a predetermined temperature so as to obtain decomposition products,
the improvement wherein the purging step includes loading the reactor with an oxyphilic solution prior to sealing the reactor and heating the interior of the sealed reactor to a first predetermined temperature to induce the oxyphilic solution to drive oxygen out of the interior of the container through said gas evacuation component.
In accordance with the present invention, the process may also include recovering said decomposition product.
In accordance with the present invention the predetermined temperature may be comprised for example between 100° C. and 225° C., when the improved batch process described herein is used for the thermal decomposition of tires.
In accordance with the present invention, the method may further comprise the step of collecting gas (including water vapor) that are evacuated through an evacuation component. This may be performed while the pressure inside said closed space (i.e., the reactor) is regulated, for example, to a substantially constant pressure; whereby a substantially anoxic environment is obtained.
In accordance with the present invention, the oxyphilic solution may comprise, for example, a proportion of approximately 10 moles of water (H 2 O) and approximately 4 moles of an alcohol selected from the group consisting of ethanol, isopropanol, n-butanol, and isobutanol, any other water-miscible alcohol and mixtures thereof, for each 4 moles of gaseous oxygen (O 2 ) present in said reactor. The oxyphilic solution may further comprise 20% (v/v) or less (0 to 20% of the total volume) of a small chain hydrocarbon selected from the group consisting of a hydrocarbon having 6 and 7 carbon atoms (e.g., hexane, heptane, 2,3-dimethylbutane, etc.) and mixtures thereof, and 2% (v/v) or less (0 to 2% of the total volume) by volume of nonionic surfactant such as polyethylene-(20)-sorbitan-monooleate (Tween® 80) or other type of nonionic surfactant such as alcohol ethoxylate, alkylphenol ethoxylate, fatty acid ethanolamine, ethylene oxide, propylene oxide block copolymer, fatty amine ethoxylate, fatty acid ethoxylate, fatty acid sorbitol ester, fatty acid sorbitol ester ethoxylate and mixtures thereof. Percentages (%) are expressed herein as volume per volume (v/v).
Also in accordance with the present invention the oxyphilic solution may comprise, for example;
a) water, in a proportion of, for example, between 50 to 60% (v/v) of the total volume; b) an alcohol selected from the group consisting of ethanol, isopropanol, n-butanol, and isobutanol, and mixtures thereof in a proportion of, for example, between 30 to 40% (v/v) of the total volume; c) a small chain hydrocarbon selected from the group consisting of hydrocarbons having 6, and 7 carbon atoms, and mixtures thereof in a proportion of, for example, between 0 to 20% (v/v) of the total volume and; d) a nonionic surfactant selected from the group consisting of Tween® 80, and other nonionic surfactant such as, for example, alcohol ethoxylate, alkylphenol ethoxylate, fatty acid ethanolamine, ethylene oxide propylene oxide block copolymer, fatty amine ethoxylate, fatty acid ethoxylate, fatty acid sorbitol ester, fatty acid sorbitol ester ethoxylate in a proportion of between 0 to 2% (v/v) of the total volume.
Further in accordance with the present invention, the oxyphilic solution described herein may be prepared from its separated components mixed prior (premixed) to their addition inside the reactor chamber. However, the (separated) components may be added directly to the reactor chamber prior to mixing. Mixing may occur during the process while the reactor is rotatably agitated (spun). In accordance with the present invention, the oxyphilic solution may be introduced into the reactor before sealing and once the reactor is sealed (in an airtight manner), the interior of the container may be heated (e.g. about 100° C.) to generate an oxygen-free environment. The reactor may further be heated by means of burners until an exothermic reaction occurs from material (e.g. rubber, tire (vehicle tires (new or used))) undergoing decomposition. The reaction (heating) may be continued (e.g., up to 435° C. or even up to 510° C.) until the desired products (e.g., carbon black, oil) are generated.
The generation of a substantially oxygen-free environment using a purge substance such as the oxyphilic solution described herein, may be initiated at low temperature (e.g. 100° C. or slightly higher, e.g., helping the vaporization of the oxyphilic solution). The vaporizing stage of the purge substance (e.g., oxyphylic solution) may then create a positive pressure due to the volume of vapor increasing drastically, which draws air (oxygen) from the drum (out of the drum).
At higher temperature (e.g., more than 225° C., i.e., when rubber is decomposing), an exothermic reaction occurs, due to the thermal decomposition of material (cracking of long chain molecules). Once the exothermic reaction takes place, the temperature and the pressure inside the drum may be allowed to rise within a continuous anoxic environment. The pressure may be maintained above atmospheric at all times and may thereafter be regulated preferably between 1 and 35 PSIG.
In accordance with the present invention, the material used in the process described herein may be a material containing hydrocarbons, which requires the use of an anoxic atmosphere in order to be decomposed in safe conditions. Accordingly, the material containing hydrocarbons may be selected from the group consisting of a tire (new tires that are rejected or discarded for imperfection or inventory surplus and/or used (vehicle) tires), a rubber material, a vinyl-polymer, a styrene-polymer, an ethylene-polymer, a synthetic fiber, a domestic waste (garbage (e.g., fruit and vegetable peel, paper, textile, plastic)), an animal waste (e.g., mammal, insect, fish, reptile) including body parts and manure, a biomedical waste (e.g., body parts, organs, tissue), a vegetation (e.g., leaf, grass, wood, seaweed), and mixtures thereof. In fact, the batch process described herein may be applied to any type of material containing hydrocarbon and mixtures thereof.
In yet a further aspect, the present method relates to an apparatus (as shown in FIG. 1 ) for the thermal decomposition of hydrocarbon containing material said apparatus comprising;
a) a closable (i.e., sealable) reactor chamber (drum) or other container which is preferably rotatable along a longitudinal axis, b) a filter (filter elements; OMNIfilter® type) coaxial with said reactor chamber is extending inside the reactor chamber of drum, parallel to coarse filter wall and back wall defining a rear sub-chamber and a front sub-chamber, c) evacuation component (means), located in said rear sub-chamber, d) a closable opening, allowing access into said front sub-chamber, e) a door, for closing said opening in an airtight manner, and; f) heating means, for heating said reactor chamber,
wherein said apparatus is able to securely process hydrocarbon containing material to a temperature of up to 510° C. (even up to 540° C.) and wherein said apparatus does not comprise a vacuum pump.
In yet a further aspect, the present invention provides an improved apparatus for a batch process used in the thermal decomposition of hydrocarbon containing material, wherein said apparatus does not comprise a vacuum pump. More particularly, air (oxygen) removal from the inside of the apparatus (drum, reactor chamber) is not performed by the use of a vacuum pump.
The apparatus used for the thermal decomposition of material containing hydrocarbons, may comprise, for example, a rotary reactor or stationary column, drive means for rotating said reactor (along a longitudinal axis), an access to load and unload material which may be closed by a door in an air-tight manner (i.e., sealed-closed). The reactor may be surrounded by a heat-insulated sheath and may be provided with burners to heat material (i.e., reactor, drum) and may further comprise pipes (i.e., evacuation component) to evacuate gas produced by the process. A system of filter elements is extending inside said reactor defining a front sub-chamber and a rear sub-chamber and may further contain a gas collecting means connected to a discharge means. Pumps may be provided to help evacuate and circulate gas. Condenser, separator and collecting tanks may also be part of the apparatus. The rotary reactor may have inner dimensions approximately as follows: diameter of eight feet, and length of twenty feet. The reactor is preferably rotatably installed inside an insulating sheath, supported on the ground and does not comprise a vacuum pump.
The present application discloses a method and apparatus for purging oxygen from a sealed container interior and a purge substance used in such method. The method is exemplified herein in an improved batch process and apparatus for the thermal decomposition of hydrocarbon containing material in a sealed reactor interior. According to the present invention the improved batch process may comprise, 1) loading the hydrocarbon containing material into and sealing the reactor, 2) purging or expelling oxygen from said reactor, and 3) heating said reactor to a predetermined temperature so as to obtain decomposition products, the improvement residing in the purging step including loading the reactor with an oxyphilic solution prior to sealing and heating the interior of the sealed reactor to a predetermined temperature to induce the oxyphilic solution to drive oxygen out of the interior of the container through said gas evacuation component. The purge substance may be for example, an oxyphilic solution as described herein. When, for example, this process is used for the thermal decomposition of tires, gases and oil may be produced along with recyclable carbon black and steel residues which remain in the reactor at the end of the decomposition stage. The oxyphilic solution, when vaporized, creates a pressure rise that may help the vapor and air containing oxygen to be evacuated from the reactor, through evacuation means. As described herein, the oxyphilic solution may be reused from batch to batch and may comprise small chain hydrocarbons (hydrocarbons having 6 or 7 carbon atoms (C6 or C7)) in addition to water and alcohol. Surfactant may also be added as a coupling agent. Using the method of the present invention, material such as rubber, vinyl-polymers, styrene-polymers, ethylene-polymers, synthetic fibers, domestic waste, biomedical waste, animal waste and vegetation or any other type of hydrocarbon containing material and mixtures thereof may be efficiently processed.
The batch process may be accomplished with successive batches of material to be decomposed. For example, a first batch of material and the substance (e.g., oxyphilic solution) are loaded (injected) into the drum and the decomposition operation is initiated. During the process, gas are recuperated through collecting means. Once the process is completed, the drum is opened, remaining solid residues (e.g., carbon black, steel) unloaded and the drum is ready to receive the next batch and so on. As it will be described in details below, the vapor is condensed and the liquid (solution) may be recycled to generate the oxyphilic solution for the following batch process.
The method of the present invention may be exemplified with an apparatus and a batch process for decomposing material (please see Example 2). The process may be accomplished in a sealed closed space wherein the substantially oxygen-free environment has been created without the use of a vacuum pump. It is to be understood that the present invention is not limited to pyrolysis or thermal decomposition process; it is rather a new technique in which batch processes may be accomplished, in an original and innovative fashion. The invention can yet be even less restrictive, in that it may be applied to any process requiring the removal (expelling) of oxygen from a closed space provided with an evacuation component (e.g., petrochemical industry equipment for thermal cracking). However, for the purposes of this application and for clarity of the description, the invention will describe, by way of examples, a batch process for the thermal decomposition of hydrocarbon containing material (e.g., rubber tires), and the apparatus used to perform it thereof.
Without being bound to a specific mechanism of action of the oxyphilic solution, one may hypothesize that upon heating, the oxyphilic solution is vaporized and as the volume of water (steam) vapor and other components (e.g., alcohol) is expanding, the pressure inside the closed space rises. One may also hypothesize that water and alcohol molecules may interact with O 2 and may help the evacuation of oxygen from the reactor. Throughout the process, the pressure inside the drum may be regulated by evacuating air to atmosphere.
The gas and oxyphilic vapor are evacuated from the drum. The oxyphilic vapor may be condensed in a condenser and the gas may be partially flared and/or directed to atmosphere; the condensed vapor (including water and oxyphilic soultion) may be recuperated. The condensed vapor may comprise for example, water, alcohol and small chain hydrocarbons (e.g., hydrocarbons having 6 or 7 carbon atoms). One of the inventive aspects of the improved batch process described herein is that the condensed vapor may be recycled to generate the oxyphilic solution for the following batch process. This minimizes the cost and the potential harm to the environment associated with discharge. In order to generate the oxyphilic solution, the composition of the condensed vapor solution may be adjusted to a desired content with, for example, water, alcohol (water miscible alcohol; e.g., ethanol, isopropanol, n-butanol, isobutanol, and mixtures thereof) and nonionic surfactant, such as for example, Tween® 80 (which does not vaporize at 100° C.) in order to generate the oxyphilic solution.
A minor disadvantage of the present method, is that slightly more time is required to process a batch of fragmented rubber material compared to methods relying on vacuum pumps and devices. Indeed, while it took approximately 15 minutes to create an almost complete vacuum inside a drum of the above-mentioned dimensions (diameter of 8 feet, length of 20 feet), it takes approximately 20 minutes to perform a substance purge (to vaporize forty to fifty imperial gallons of solution) inside the drum. However, considering the economy in the vacuum pump, seals, and electricity and the potential risk that is avoided, the method of the present invention remains very advantageous over previously used methods.
As used herein, the term “substance purge” relates to the use of a purge substance being able to increase the pressure inside a container (under appropriate conditions such as, for example, heating up to the boiling point of said substance) helping (or inducing) the evacuation of oxygen from the container through an evacuation (means) component. A “substance purge” more particularly relates to the evacuation (removal) of air (oxygen) from the inside of a closed space using a substance such as, for example, an oxyphilic solution. A “substance purge”, as defined herein, may rely, for example, on the ability of a purge substance (e.g., a liquid or solid that may be transformed into a gas) to create a pressure increase inside a closed space (e.g., a reactor) with rise in temperature from ambient (or room temperature) to the predetermined temperature referred to herein, that will help the evacuation of air through an evacuation component. An example of “substance purge” may be for example the removal of oxygen by use of a liquid, such as the oxyphilic solution described herein, which upon heating will be vaporized and will contribute to the increase in pressure that is required to allow the evacuation of air.
As used herein a “purge substance” is a substance that may induce the evacuation of oxygen (a substance purge), out of the interior of the container when the interior of the reactor is heated to a predetermined temperature.
As used herein, the term “oxyphilic solution” relates to a solution which, in its vaporized states helps the evacuation of oxygen from a closed space. An “oxyphilic solution” relates to a solution, which comprise, for example, water (H 2 O) and/or alcohol (e.g., ethanol, isopropanol, n-butanol, isobutanol). An “oxyphilic solution” as used herein may further comprise other molecules than water or alcohol molecules, such as, for example, small chain hydrocarbons having 6 or 7 carbon atoms and mixtures thereof and/or surfactant (e.g. nonionic surfactant) without its property being affected.
As used herein a “oxygen-free environment” or a “anoxic environment” relates to environment (air contained in a container or reactor) containing negligible quantity of oxygen (less than 0.1% and not exceeding 1% (v/v) of the total air volume) that avoids risks associated with a thermal decomposition process as described herein.
As used herein the terms “oxygen purge” or “purging oxygen” or “oxygen purge step” relates to the removal (evacuation, expelling) of oxygen from the inside of a reactor (drum, reactor chamber) using either mechanical means (e.g., vacuum pumps) or other means such as, for example, the use of a substance purge (using, for example, an oxyphilic solution).
As used herein, the term “small chain hydrocarbon” includes compounds comprising, for example 6 or 7 carbon atoms (C6 or C7). “Small chain hydrocarbon” includes n-alkanes, branched alkanes, cycloalkanes, alkenes such as but without being restricted to hexane, heptane, 2,3-dimethylbutane, tetramethylethylene, etc. It is to be understood herein, that “small chain hydrocarbons” suitable for the oxyphilic solution described herein are small chain hydrocarbons (e.g. C6 or C7 hydrocarbon and mixtures thereof) able to be vaporized at temperatures near/between 100° C. and 120° C. (e.g., water which has a boiling point near 100° C.) and that may be condensed (i.e., condensable) at temperature below 100° C.
It is to be understood herein, that if a “range” or “group” of substances or the like is mentioned with respect to a particular characteristic (e.g. temperature, pressure, time and the like) of the present invention, it relates to and explicitly incorporates herein each and every specific member and combination of sub-ranges or sub-groups therein whatsoever. Thus, any specified range or group is to be understood as a shorthand way of referring to each and every member of a range or group individually as well as each and every possible sub-ranges or sub-groups encompassed therein; and similarly with respect to any sub-ranges or sub-groups therein. Unless otherwise indicated, percentages (%) are expressed on a basis of volume/volume (v/v).
with respect to a pressure range of 1 to 35 PSIG, it is to be understood as specifically incorporating herein each and every individual pressure state, as well as sub-range, such as for example 2 PSIG, 5 PSIG, 20 PSIG, 34.5 PSIG, 5 to 8 PSIG, 5 to 35 PSIG, 10 to 25 PSIG, etc.; with respect to a temperature of at least 100° C., this is to be understood as specifically incorporating herein each and every individual temperature state, as well as sub-range, comprising 100° C. and above 100° C., such as for example 101° C., 105° C. and up, 115° C. and up, 102° C. to 150° C., up to 210° C., and 600° C. etc.;
TABLE 1
Abbreviation
Meaning
° C.
degree Celcius
rpm (RPM)
revolution per minute
ppm (PPM)
parts per million
BTU
British thermal unit
lb
pound
%
percent
mg
milligram
kg
kilogram
kPa
kiloPascal
cSt
Centistoke
PSI
Pound per square inch
PSIG
Pound per square inch gauge
m 3
Cubic meter
U.S.
United States
ft 3
Cubic feet
T.H.C.
Total hydrocarbon content
L
liter
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 . is a schematic diagram of a thermal decomposition apparatus using an oxyphilic solution to obtain an anoxic atmosphere for carrying out the improved batch process of the invention.
DETAILED DESCRIPTION OF THE INVENTION
It is the gist of the invention to provide a method of purging oxygen from a sealed container interior without having to create a vacuum and a purge substance used in such method. Such substance purge may be performed by using a purge substance such as, for example, an oxyphilic solution, which upon heating and vaporization, may generate a positive pressure (i.e., above atmospheric pressure) helping the evacuation of oxygen (O 2 ) out of the reactor, through evacuation components. The removal of oxygen is exemplified in an improved batch process described herein and it may be sufficient to allow the thermal decomposition of material in safe conditions.
In a rotary drum, or other enclosure having a diameter of 8 feet and a length of 20 feet (or a similar volume), a volume of approximately 182 to 227 L (40 to 50 imperial gallons) of oxyphilic solution may be used. Such oxyphilic solution may comprise, for example, approximately 50% (v/v; i.e, of the total volume) to 60% (v/v, i.e., of the total volume) of water, 40% (v/v, i.e., of the total volume) of alcohol, such as for example ethanol, isopropanol, n-butanol, and isobutanol and mixture thereof, 20% (v/v, i.e., of the total volume) of small chain hydrocarbons (e.g. C6 to C7 hydrocarbon and mixtures thereof) and 2% (v/v, i.e., of the total volume) of surfactant such as polyethylene-(20) sorbitan-monooleate. The total volume of the oxyphilic solution may be adjusted for a reactor of different size. Vaporization of the solution and removal of oxygen from the reactor may be completed in about 10 to 20 minutes as it is exemplified herein.
Referring to FIG. 1 ; this FIGURE is an example embodiment showing the flow diagram of a thermal decomposition system (apparatus), used to exhibit the inventive elements of the present invention. More particularly, it can be seen that the apparatus used may comprise; a rotary cylindrical reactor or drum ( 10 ), which is rotatably installed inside an insulating sheath (not shown) resting on the ground, as known in the art. The drum ( 10 ) defines a front ( 10 a ) and a back end walls ( 10 b ), and rotates about a horizontal axis. Burners ( 21 ) are provided inside the sheath, to heat the exterior of the cylindrical chamber of the rotary drum or kiln ( 10 ) to selected controlled temperatures. The drum ( 10 ) comprises an opening ( 12 ) at its front end ( 10 a ), through which batches of material (e.g. fragmented material) to be decomposed may be loaded, more particularly in section ( 10 d ) of drum ( 10 ). A sealed door ( 14 ) closes the opening ( 12 ). The drum ( 10 ) may have a diameter of 8 feet and a length of 20 feet, or other pre-determined dimensions.
An outlet pipe ( 16 ) originates inside the drum ( 10 ) and extends through the back wall ( 10 b ) of said drum ( 10 ). Gas collecting (including an evacuation component), which will be detailed hereinafter, are provided at the inner end of pipe ( 16 ), i.e. in the portion of pipe ( 16 ) located inside the inner chamber of drum ( 10 ). A rotary sealing joint ( 18 ) allows a sealed engagement of pipe ( 16 ) with drum ( 10 ).
The outlet pipe ( 16 ) is connected to the flow circuit of the batch process of the invention, comprising elements, which are known in the art, except as noted hereinafter, and which will consequently only be briefly described.
The outlet pipe ( 16 ) draws the gas and vapor from inside the chamber of drum ( 10 ) with the help of a process pump ( 19 ). Pipe ( 16 ) is connected to a condenser ( 20 ) which brings (condenses) the gas and vapor emanations into their liquid phase (e.g., those of which are condensable under such the conditions described herein). At a temperature ranging from 100° C. to 165° C. a condensed liquid, containing water, alcohol and small chain hydrocarbons such as for example C6 to C7 hydrocarbons is collected separately from the gas and oil. At a temperature around 340° C., an exothermic reaction is initiated generating hydrocarbon vapors which are carried to a phase G/O separator ( 22 ) forming gases (non-condensable) and oils (condensable); following separation, the oil is then carried into an oil storage tank ( 23 ), and the gases can be flared ( 24 ) for obtaining a desired total hydrocarbon content and then stored in a process gas tank ( 25 ). The process gas, which has been thus created may be used by the burners ( 21 ) to heat the exterior wall of rotary drum ( 10 ). The pump ( 19 ) may have a pressure range of 1 to 35 PSIG. Cooling of said pump ( 19 ) is provided by water tank ( 30 ).
The drum ( 10 ) according to the invention may comprise, for example, gas collecting means, fluidingly connected to the inner end of outlet pipe ( 16 ). One of the preferred embodiment of gas collecting means is shown in FIG. 1 as a rotatable collecting unit with filter elements ( 26 ) fixed to wall end ( 10 b ), on which twelve ( 12 ) radially projecting filter elements ( 27 ) are provided. These filters have an open end, and are screwed around a manifold flanged to wall ( 10 b ) and to outlet pipe ( 16 ).
Collecting unit with filter elements ( 26 ) is located in section 10 c of the reactor chamber of drum ( 10 ), parallel to coarse filter wall ( 28 ) and its back wall ( 10 b ). Filter elements ( 27 ) may be provided with suitable micropores of high resistant material therein.
A circular coarse wall filter ( 28 ) is fixed radially to the cylindrical inner wall of drum ( 10 ) inside the drum chamber, and is located before collecting unit with filter elements ( 26 ) and near back wall ( 10 b ), so as to define a relatively lengthwise short, diametral rear pocket forming a rear sub-chamber ( 10 c ) inside the main reactor chamber of drum ( 10 ). Gas collecting unit with filter elements (OMNIfilter®-like filters) ( 26 ) is located in pocket ( 10 c ). The drum main chamber is thus divided into a small sub-chamber (i.e., rear sub-chamber) ( 10 c ), and a large sub-chamber (i.e., front sub-chamber) ( 10 d ), extending between filter wall ( 28 ) and drum front wall ( 10 a ). An opening ( 12 ) gives access into a front sub-chamber ( 10 d ), where the (fragmented) material to be processes is to be loaded. The purpose of filter ( 28 ) is to prevent rubber shreds to reach the rear sub-chamber pocket ( 10 c ) and damage filter elements ( 27 ) (OMNIfilter®-like filters) around the collective unit with filter elements ( 26 ). Only gas and vapor are allowed through filter ( 28 ). For example, the filter ( 28 ) may comprise several juxtaposed perforated plates, which have a plurality of relatively offset through-holes of a small dimension. For example, three superimposed plates may be used, the first one (facing wall ( 10 a )) with holes of ⅛″, the second intermediate one with holes of 1/16″, and the third one (facing wall ( 10 b )) with even smaller holes, e.g. 1/32″. The plates are configured so that the holes may allow gas to flow through without allowing solid particles to gain access to the rear sub-chamber pocket. Thus, the effective spacing between the holes is designed to block macroparticulate material from passing through, while allowing liquid to seep in and gaseous emanations to pass through.
In accordance with the present invention, the process used to validate the invention includes the step of providing a predetermined volume of an oxyphilic solution inside the rotary drum ( 10 ), at the same time as the material to be decomposed is loaded. For example, for a drum having the above-mentioned dimensions, forty to fifty imperial gallons of solution may be inserted in the drum. The solution will vaporize in the drum being heated (at 100° C.) at the beginning of the process. The process pump is not activated at this stage since the pressure inside the reactor (due to the vapor) is above atmospheric pressure. A pressure range within the drum of between 1 and 15 PSIG is maintained and it is necessary to transfer through outlet pipe ( 16 ) the vapor (from water and hydrocarbons) from the drum ( 10 ) to condenser ( 20 ) and gas/liquid (G/O) separator ( 22 ).
The purpose of the oxyphilic solution will now become apparent. Indeed, as the solution starts to vaporize, it will effectively contribute to raise the pressure inside the drum that in turn will generate a continuous air and vapor flow into the outlet pipe ( 16 ) mainly due by pressure difference. Thus, air (containing oxygen) will be effectively expelled out of the drum ( 10 ), into pipe ( 16 ).
Forty to fifty imperial gallons of said solution creates approximately 11,000 to 13,500 cubic feet of vapor. A drum with the above-noted dimensions has an inner volume of approximately 1,000 cubic feet. Thus, the total volume of vapor, which originates from the liquid inserted in the drum, is equivalent to approximately eleven to thirteen times the inner volume of the drum. Once all the solution has evaporated, the inner concentration of oxygen will be inferior to approximately 0.1% (of the air content inside the apparatus) and thus a substantially oxygen-free environment is effectively created.
The oxyphilic vapor that is evacuated in pipe ( 16 ) will be condensed in the condenser ( 20 ) and collected in liquid phase in the separator ( 22 ), to be stored in a suitable tank and re-used in the next batch. It must be noted that this liquid collecting means must be present in any event, since a certain quantity of integral water present in tire rubber must be collected anyway. The tank must be larger however, to accommodate larger volumes of water derived from the humidity contained in rubber ±3% (v/v).
Thus, it can be seen that in accordance with the present invention, a substantially anoxic (oxygen-free) environment may be created in a sealed closed space without a vacuum being created therein. Air is eliminated from the drum ( 10 ) mainly by pressure difference upon vaporization of water and light hydrocarbons. Without the present invention, a vacuum pump must be utilized and the electricity required to drive such equipment is an additional expense that increases the cost of the process. On the other hand, the energy needed to vaporize the oxyphilic solution of the present invention is provided by the burners, which are fed with the process gas resulting from the thermal decomposition of the material inside the drum. Thus, with this energy source, no outer expense has to be anticipated.
EXAMPLE 1
The following result, illustrated in Table 2 is an example of the method disclosed herein, using the apparatus illustrated in FIG. 1 . As a blank experiment, a volume of between 40 and 50 imperial gallons of freshly prepared oxyphilic solution was introduced in the drum ( 10 ). The drum was subsequently sealed. The temperature inside the drum ( 10 ) was raised and maintained at 100° C. Concentration of oxygen inside the drum was followed by a continuous analyzer using a chemical cell. Column 2 illustrates the volume of air (containing approximately 20.9% of O 2 of the total air content (i.e., in percent by volume at 15° C. and 101.3 kPa) initially contained in the reactor that is gradually replaced by the volume occupied by the vaporized oxyphilic solution, as seen in column 3. As may be seen, from this example (Table 2), after 12.4 minutes, the volume of air containing O 2 is negligible (0.147 cubic feet (ft 3 )). It may take less than 15 minutes to completely replace air with the vaporized oxyphilic solution using the conditions described above. Such conditions are considered extremely safe since the interior of the reactor contains only steam (water vapor) and hydrocarbon vapors (originating from the oxyphilic solution). The operation results in a positive pressure inside the reactor, thus preventing air infiltration.
TABLE 2
2
4
Volume of
3
Volume of air (ft 3 )
air (ft 3 )
Volume of
evacuated from
1
(20.9% O 2 )
vaporized oxyphilic
reactor/volume
Time
inside the
solution (ft 3 )
of vaporized oxyphilic
(Minutes)
reactor
inside the reactor
solution (ft 3 )
0
1000
0
0
1
500
500
500/500
2
250
500
250/250
3
125
875
125/875
4
62.5
937.5
62.5/938
5
31.3
968.7
31.3/969
6
15.65
984.4
15.65/984
7
7.83
992.2
7.83/992
8
3.91
996.1
3.91/996
9
1.95
998.0
1.95/998
10
0.975
999.0
0.98/999.0
11
0.49
999.5
0.49/999.5
12
0.245
999.7
0.25/999.7
12.4 (final)
0.147
999.85
0.15/999.9
EXAMPLE 2
The following is an example of an improved batch process based on the process described in U.S. Pat. No. 5,821,396, wherein an oxygen-free environment is generated using the method and oxyphilic solution described herein.
A drum ( 10 ) of 20 feet in length and 8 feet in diameter was used. Six tons (12 000 pounds) of used rubber tires which is equivalent to about 600 tires were first cut up in pieces of about 2″×2″ and loaded as tire cuttings into the stationary reactor drum with the reactor access door ( 14 ) at 12:00 o'clock. Forty-five (imperial) gallons of the oxyphilic solution containing water (56% (v/v) of total volume), alcohol (36% (v/v) of the total volume), small chain hydrocarbons (comprising a mixture of C6 and C7 hydrocarbons; 7% (v/v) of the total volume)) and polyethylene-(20)-sorbitan-monooleate (0.2 L, i.e., less than 1% (v/v) of the total volume) was added inside the reactor. The door was closed in an airtight manner. The drum was then driven at low speed of 0.75 RPM at a temperature of 100° C. and higher. At this step the oxyphilic solution becomes vapor, which gathers air contained in drum (which may be partially due to molecular interaction between water/alcohol and O 2 ) and through expansion, carry air out of the drum. The burner ( 21 ) was started using propane gas from a reservoir at the start of first batching operation. Heating was carried out at about 50% of the burner capacity for 10 minutes then 90% of the burner capacity for the consecutive 35 minutes. At this time evaporation of the oxyphilic solution was starting to take place which then draw air and oxygen outside the drum, thus creating the required anoxic environment. This is followed by an exothermic reaction starting at about 225° C. whereby heating was lowered to 10% of burner capacity and valve was closed to thus positively prevent secondary cracking reaction and to allow reactor internal pressure to increase by the production of process gases and vapors which started to be discharged through condenser ( 20 ) and separated in G/O separator ( 22 ) with oil going to reservoir ( 23 ) and the process gases to reservoir ( 25 ). Process gases with a carbon content of lower then 35% (35% total carbon content (T.H.C.)) as measured by the relevant sensor were first directed to flare ( 58 ) by opening a solenoid valve and when analyzed to a 35% T.H.C. (35% total carbon content) were directed to a reservoir. When sufficient process gas has accumulated within reservoir as indicated by the pressure sensor, liquid ring pump was started. The process gases were fed to the burner ( 21 ) and the burner was modulated between 10% and full capacity by a motorized butterfly valve as controlled from the computer.
The pressure inside the drum (reactor) ( 10 ) was regulated between 760 and 1277 mm of mercury, so as to obtain maximum output of oil relative to the output of the process gas. To do so, reactor rotation and heating were modulated and only at the end of batch operation when gas output started to decrease, was it necessary to start liquid ring pump. The temperature at the inlet of the condenser ( 20 ) as determined by temperature sensor varied during the entire batch processing operation between 400° C. and 496° C., while the temperature at the outlet of the condenser ( 20 ) as determined by another temperature sensor was varied between 40° C. and 52° C.
These pressure and temperature conditions and also the low drum rotational speed were kept until the total hydrocarbon content of the separated process gases became less than 50% (50% total carbon content (T.H.C.)) at which time drum rotation was increased from 0.75 RPM to about 8 RPM for about 4 minutes and the speed was lowered again to 0.75 RPM, this cycle was repeated three times. Due to the rapid stirring, solid residual material in the drum started to emit process gas again. At the end of the third stirring cycle, flare stopped when the total carbon content of the process dropped to about 1 to 2% (T.H.C.).
During the entire batching operation, effluent gases from the burner ( 21 ) were monitored as to their composition by the sensors and chimney butterfly valve and combustion air fan were consequently modulated so as to discharge to the atmosphere environmentally acceptable combustion gases.
The drum was stopped with its door at 12 h00, the door ( 14 ) was opened and replaced by a dummy door. The drum ( 10 ) was then rotated to a position with the dummy door at 6 h00, the dummy door was removed and the suction tube of a vacuum cleaner was held at about 18 inches from the door so as to prevent escape to the atmosphere of any powder in the drum. The suction tube, about 26 feet in length, was inserted within the drum and moved longitudinally of the drum to suck out the solid residues namely carbon black powder and wire mesh which were sent to a separator so that the carbon black powder was recuperated. Steel wire mesh from the rubber tires were also recuperated.
Total batching time for processing 12,000 pounds of tires took approximately three hours and twenty minutes.
The following components were obtained expressed as a function of the percentage of the total weight of tires which were processed: 47% light oil which is equivalent to about 1.3 U.S. gallon per tire, process gas 11%, carbon black 32% and steel 10%. The carbon black was of quality to be sold for use, for instance as dry ink in photocopying machines, filtering agent, tire fabrication, paint and dye colorant, synthetic marble and plastic.
Oil analysis: An oil sample was supplied to a commercial laboratory and the following data was obtained: Density at 15° C.: 918.3 kg/m3; calorific value 1767.2 BTU/lb.; ketone index 34.5; viscosity at 40° C. 3.94 cSt; ashes 0.011% m. The oil was submitted to distillation; the initial boiling point was 64° C., 10% of the oil was recuperated at 137° C., 20% at 178° C., 30% at 220° C., 40% at 259° C., 50% at 299° C., 60% at 331° C., 70% at 358° C. and 90% was recuperated at 399° C. Cracking occurred at 92% of recuperation at 402° C., the flash point was 22° C., X-ray analysis showed a sulfur content of 0.53% m and a total halogen content of 713 ppm.
The carbon black obtained was also analyzed for impurities with the following results; arsenic 1.71 mg/kg; cadmium 4.60 mg/kg; chlorides 2210 mg/kg, chrome 9.50 mg/kg; mercury less than 0.05 mg/kg; nickel 11.5 mg/kg; lead 144 mg/kg, sulfur 30 g/kg and zinc 48500 mg/kg. When burnt at 800° C., there was a carbon black loss of 83.9% of the carbon black sample.
It was found that 10 to 15% of the process gas obtained could be sold as fuel gas, being in excess to the process gas required for heating the reactor during the batch processing operation. The used tire recycling process in no way contaminated the atmosphere surrounding the reactor as it was found very easy to prevent escape of carbon black during reactor unloading.
It should be noted that propane gas is used as a source for the burners only at the start of the first batch operation since sufficient process gas is accumulated in reservoir during the first batching operation for the start of the second and the subsequent batch operations.
It was also found that four reactors ( 10 ) including chimney, burner ( 21 ) and immediate accessories could be installed in parallel to discharge gas to single processing equipment including the condenser ( 20 ) separator ( 22 ), reservoir, pumps and other associated equipment so as to practically double the capacity of the installation.
The excess process gas in addition to that required for heating the reactor could be used as a fuel, for instance, for steam production. | 4y
|
BACKGROUND OF THE INVENTION
This invention relates to a fuel supply system for gaseous fuel operated vehicle engines, which is adapted to supply a compressed natural gas (CNG) to an engine after decompressing and mixing with air, and to a regulator suitable for use in the fuel supply system.
Recently, natural gases are re-evaluated as a substitute energy source for petroleum, and attempts are being made to use natural gases as a fuel for motor vehicles. The primary difference of the natural gase from petroleum resides in that the natural gas contains methane of low boiling point as a major component in contrast to the petroleum gas which is mainly constituted by propane and butane of relatively high boiling points. Accordingly a difficulty is encountered when using the natural gas as a fuel of motor vehicles because it is difficult to store it in liquefied form at normal temperature in the fashion of the liquefied petroleum gas (LPG) which is used as a fuel on certain kinds of motor vehicles. It is therefore the usual practice to store the natural gas in the form of compressed natural gas (CNG).
On a motor vehicle which uses CNG as a fuel, CNG which is normally contained in a bomb under high pressure, for example, under pressure of 200 kg/cm 2 is decompressed, for example, to the atmospheric pressure by a regulator and supplied to an engine after mixing it with air by a mixer which is constituted by known component parts including a venturi. Citing an example of actually commercialized cars, the CNG bomb is mounted in a luggage room section, namely, in the trunk room in case of a passenger car and on the loading platform in case of a truck, and the fuel gas is supplied from the bomb under high pressure to a regulator which is located in the engine room.
As the regulator is required to decompress the fuel gas to a great degree as mentioned hereinbefore, it is usually constituted by two or a larger number of integral or separate decompression stages. Anyway, the regulator is mounted in an engine room section of a vehicle, necessitating to extend a high pressure gas conduit to the engine room section from the bomb in the trunk across a passenger's room section. Needless to say, greater the length of the high pressure conduit, higher becomes the possibility of gas leakage from joint or other portions of the pipe.
There has also been known a regulator of the type which employs a diaphragm in association with a gas flow control valve, the diaphragm being responsive to the air pressure in a decompressing chamber to control the gas flows into the decompressing chamber from a high pressure gas passage led from a fuel gas bomb. This arrangement is used in two or a greater number of separate or integrally combined decompressing stages to depressurise the CNG from the bomb, for example, from 200 kg/cm 2 to the atmospheric pressure (Japanese Laid-open Patent Application No. 59-165852).
However, the pressure reduction by such an arrangement involves a problem that the terminal open end region of the high pressure gas conduit is cooled by adiabatic expansion of the fuel gas as it is released into the decompressing chamber from the high pressure conduit, freezing propane, butane, water or other gas components of relatively high melting point in that region, especially in the high pressure gas conduit, as a result narrowing the effective area of the conduit to block the fuel gas flow and lowering the performance quality of the engine.
In order to prevent water vapor in the gas from freezing due to adiabatic expansion of the gas during the sudden decompression, there has been proposed a regulator which is arranged to heat the circumference of the high pressure gas conduit by the use of cooling water which has been heated by the engine operation. However, in a case where the regulator is positioned in the vicinity of a fuel gas bomb in a luggage room section in the rear portion of a vehicle for reducing the length of the high pressure gas conduit to a minimal, the heating effect is lowered by heat dissipation from the cooling water conduit which has to be extended over a long distance between the engine room in the front portion of the vehicle and the luggage room in the rear portion.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a fuel supply system for gaseous fuel operated vehicles, which has a shortened high pressure conduit for supply of a gaseous fuel.
It is another object of the invention to provide a regulator for a gaseous fuel operated engine, which is capable of preventing constriction or blocking of a high pressure gas conduit due to freezing of fuel gas components therein.
It is still another object of the invention to provide a regulator for a gaseous fuel operated engine, which can suitably prevent constriction of a high pressure gas conduit due to freezing of fuel gas components therein, even in a case where the regulator is located in the vicinity of a fuel gas bomb in a luggage room section remote from an engine room of a vehicle.
In accordance with an aspect of the present invention, there is provided a fuel supply system for a gaseous fuel operated vehicle engine, in which a compressed gas from a bomb is decompressed and then mixed with air to supply an air-fuel mixture to the engine. As illustrated in FIG. 1, the regulator is divided into at least two units, locating an upstream regulator 1 and a fuel gas bomb 2 in a luggage room section 3 of a vehicle, locating a downstream regulator 4 and a mixer 5 in an engine room section 6, and interconnecting the upstream and downstream regulators 1 and 4 by a low pressure conduit 8 which is extended across a passenger's room section 7 of the vehicle.
The mixer 5 may be formed either integrally with or separately from the engine. In case the regulator is divided into two units, the upstream and downstream regulator units constitute primary and secondary regulators, respectively. Accordingly to the present invention, no limit is put on the number of the upstream or downstream regulator units in a case where regulator is divided into three or more units.
As shown in FIG. 2, a fuel cutoff valve 9 which is in association with an ignition switch is provided in the fuel gas conduit in a position immediately behind the fuel bomb 2, namely, in a position between the bomb 2 and the upstream regulator 1, thereby cutting off the supply of the high pressure fuel gas while the vehicle is at rest to minimize those portions which are constantly subject to high pressure.
The high pressure fuel gas which is supplied to the upstream regulator 1 from the bomb 2 is decompressed to several kg/cm 2 , and then supplied to the downstream regulator 4 through a low pressure conduit 8. After further depressurizing the gas to the atmospheric pressure by the downstream regulator 4, it is mixed with air by the mixing device 5 and fed to the engine 10.
In this manner, the fuel gas flows through the low pressure conduit 8 after decompression by the upstream regulator 1, so that there is no necessity for extending a high pressure conduit which is required to endure a high pressure equivalent to the pressure in the bomb 2 as seen in the conventional arrangement. Consequently, it becomes possible to provide a safer fuel supply system at a lower cost. Besides, according to the present invention, the downstream regulator 4 is located in the engine room section of the vehicle, thereby preventing deteriorations in engine performance or starting failures due to delay of fuel which would occur in transient operating conditions in a case where the fuel is passed through a lengthy flow passage after the pressure reduction to the atmospheric pressure at the downstream regulator 4. Namely, the just-mentioned problems can be eliminated by shortening the fuel flow passage between the downstream regulator 4 and mixing device 5.
In accordance with another aspect of the present invention, there is provided a regulator for a gaseous fuel operated vehicle engine, in which the pressure of a fuel gas in a high pressure gas conduit is decompressed to a predetermined level by opening and closing the terminal open end of the conduit, which is in communication with a decompressing chamber, in response to the gas pressure prevailing in the decompressing chamber, the regulator essentially including a fuel cutoff valve provided in the high pressure gas conduit for cutting the fuel gas supply when the engine is not running or at the time of emergency, and a PTC heater located around the terminal open end of the high pressure gas conduit and having a resistance with a positive temperature coefficient.
The PTC heater is one of functional ceramics which are increasingly adopted for practical uses, and consists of a PTC (positive temperature coefficient) thermistor with an electric resistance which increases considerably with temperature increases.
Since the electric resistance of the PTC heater increases with elevation of its own temperature as mentioned above, it has a self-adjusting temperature control function, varying the current flowing through a heat generating portion when applied with a predetermined voltage during operation of an engine. Namely, it permits to supply a sufficient amount of heat to a required portion by an extremely simple electric circuit.
With the regulator for gaseous fuel operated engines according to the present invention, the fuel gas begins to flow upon starting an engine, and the temperature of the component parts around the terminal end of the high pressure gas conduit drops due to adiabatic expansion of the fuel gas. However, in this low temperature state, the PTC heater has a small resistance, permitting flow of relatively large current to heat up the component parts around the terminal end in an accelerated manner. As the temperature of the circumventive parts and the PTC heater itself are elevated, the resistance of the PTC heater is correspondingly increased until reaching a constant temperature where the amount of heat dissipation of the heater balances with the amount of electric consumption, thereby self-controlling the temperature to that constant level.
In this manner, the temperature drop is stopped in spite of the adiabatic expansion of the fuel gas, preventing freezing of fuel gas components which would lead to constriction of the high pressure gas conduit.
In accordance with still another aspect of the present invention, there is provided a regulator for gaseous fuel operated vehicle engines, in which the pressure of a fuel gas in a high pressure gas conduit is reduced by opening and closing a terminal open end of the high pressure gas conduit, which opens into a decompressing chamber, in response to the pressure prevailing in the pressure reducing chamber, the regulator including a fuel cutoff valve provided integrally in the high pressure gas conduit on the upstream side of the terminal open end thereof, and a heat pipe located between an exhaust system of the engine and the regulator having one end thereof connected to the exhaust system and the other end to a part in the vicinity of the terminal open end of the high pressure fuel gas conduit.
The heat pipe has an operating liquid sealed therein to transfer heat from a zone in contact with a high temperature portion to a zone in contact with a low temperature zone by evaporation and condensation of the operating liquid. The regulator for gaseous fuel operated engine according to the invention employs a heat pipe which has one end thereof connected to the exhaust system of an engine and the other end located around the terminal open end of a high pressure gas conduit, so that part of the thermal energy of the exhaust gas is supplied to relatively low temperature portions around the terminal open end of the conduit through the heat pipe, thereby heating the circumference of the terminal end to prevent freezing of fuel gas components in the high pressure gas conduit.
The above and other objects, features and advantages of the invention will become more apparent from the following description and the appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings;
FIG. 1 is a block diagram showing the basic configuration of the invention;
FIG. 2 is a block diagram showing the basic configuration of the invention in a practical form;
FIG. 3 is a schematic perspective view of a truck incorporating the present invention:
FIG. 4 is a schematic perspective view of a passenger car incorporating the present invention;
FIG. 5 is a partly sectioned view of a embodiment of the regulator for gaseous fuel operated engine, suitable for use with the fuel supply system according to the invention;
FIG. 6 is a sectional view taken on line VI--VI of FIG. 5;
FIG. 7 is a block diagram of a vehicle mounting a regulator with a heat pipe;
FIG. 8 is a schematic perspective view of a vehicle mounting a regulator with a heat pipe;
FIG. 9 is a partly sectioned view of another embodiment of the regulator for gaseous fuel operated engine, suitable for use with the fuel supply system according to the invention; and
FIG. 10 is a sectional view of a heat pipe.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereafter, the invention is described by way of preferred embodiments shown in the drawings, in which the component parts having correspondences in the basic configuration of FIG. 1 are designated by the same reference numerals.
Referring to FIG. 3, there is illustrated an example of a truck incorporating the fuel supply for gaseous fuel operated vehicle according to the invention. As shown in this figure, the truck 20 can be divided into an engine room section 6 for accommodating an engine and associated parts, a driver's room section 7 with a seat, and a rear freight room section 3 with a loading platform. The fuel gas bomb 2 is formed, for example, from a metal and fixed in the freight room section 3 by the use of a belt and bolts. The bomb 2 is charged with a compressed fuel gas, for example, under pressure 150-200 kg/cm 2 in freshly charged state. This fuel gas is led out through a bomb valve 11 which is fixedly clamped to the bomb 2. Indicated at 12 is a high pressure conduit which connects the bomb valve 11 with a primary (upstream) regulator 1 which is fixed in the freight room section 3 in a manner similar to the bomb 2, and which pays sufficient considerations to safety since it is subjected to substantially the same pressure as the bomb 2.
The primary regulator 1 is a decompressing valve employing a diaphragm as will be described hereinlater, regulating the fuel gas substantially to a constant pressure level, for example, to a level of 5 to 6 kg/cm 2 when the bomb 2 is filled with more than a predetermined amount of fuel gas. Denoted at 9 is a fuel cutoff valve which is formed integrally with the primary regulator 1, and which is constituted, for example, by a high pressure electromagnetic valve and associated with an ignition switch or the like to cut off the supply of fuel gas when the vehicle is at rest or at the time of emergency.
On the other hand, accommodated in the engine room 6 is a secondary (downstream) regulator 4, an engine 10 and a mixer 5 which is attached to the engine. The secondary regulator 4 and mixer 5 are interconnected by a lo pressure hose 13 of rubber or similar material. Similarly to the primary regulator 1, the secondary regulator 4 consists of a decompressing valve with a diaphragm, for reducing the atmospheric pressure the fuel gas which is fed from the primary regulator 1 through a low pressure conduit 8 extended across the driver's cabin section 7, for example, in a lower portion of the vehicle body in that section. After decompression by the secondary regulator 4, the fuel gas is led into the aforementioned low pressure hose 13.
When the vehicle operates exclusively on CNG, the mixer 5 may be incorporated into the engine 10 in a manner similar to a carbureter of the gasoline engine. However, in a case where the vehicle uses gasoline in addition to CNG, it is desirable to mount the mixer 5 in the vicinity of a carbureter, not shown, or to form the mixer 5 integrally with a cabureter, sucking out the fuel gas from the downstream regulator 4 through the low pressure hose 13 in an amount corresponding to the amount of induction air by the vacuum which is generated by a component like a venturi nozzle. The low pressure hose 13 is desired to be as short as possible to cope with abrupt changes in the required amount of fuel.
In a case where the vehicle also operates on gasoline, the operation of the fuel cutoff valve, changeover of the fuel system, fuel supplying operation and resetting of the spark advance characteristics due to the change of fuel may be controlled by an electronic circuit such as a micro-processor or the like.
Referring to FIG. 4, there is illustrated an example of a passenger car incorporating the present invention, in which those parts common to the basic arrangement of FIG. 1 and the truck of FIG. 3 are designated by the same reference numerals. In this case, the passenger car 20' can be divided into an engine room section 6' accommodating an engine and associated parts, a passenger's room section 7' with seats, and a luggage room section 3' including a trunk room or the like. The arrangement, construction and operation of the fuel supply system of the invention are same as in the case of the truck 20 of FIG. 3, and therefore the description in these aspects is omitted here to avoid repetitions.
Referring to FIG. 5, there is shown in section an embodiment of the regulator which is suitable for use in the fuel supply system of the invention, particularly for use as the primary regulator of the system.
The primary regulator 1 includes a high pressure casing or housing 14 which is attached with a fuel cutoff valve 9, a low pressure casing or housing 16 which is assembled with decompressing parts, and a PTC heater 15 interposed between the two casings 14 and 16. The high pressure casing 14 interiorly defines a fuel cutoff chamber 17 which is in communication with a first high pressure gas passage 19 connected to a high pressure conduit from a bomb, not shown, and with a second high pressure gas passage 23 leading to a decompressing chamber 21 formed in the low pressure casing 16.
The fuel cutoff valve 9 is provided with a fuel cutoff needle valve 25 which is movable up and down in the fuel cutoff chamber 17, and an electromagnetic coil, not shown, for driving the needle valve 25, and fixed to the high pressure casing 14 by screws 27. The electromagnetic coil is connected to a battery 31 through a switch 29 which is operationally linked to an ignition switch, not shown, driving the needle valve 25 downward into abutting engagement with a conical wall 33 in a lower portion of the fuel cutoff chamber 17 to block the downward flow of the fuel, for example, when the engine is at rest. The switch 29 is not necessarily required to be a mechanical switch, and may be constituted by an electronic circuit with a switching function, for example, a function of turning on an off in response to a signal of an emergency sensor or the like.
Formed in a lower portion of the high pressure casing 14 is a valve chamber 35 in which a valve 37 is loosely fitted. The valve 37 has a non-circular shape in section with protuberances or recesses on its circumference as shown in FIG. 6, and operates to block the downward flow of the fuel when it is in intimate contact with a terminal open end 38 of the second high pressure passage 23, and to spout the fuel gas into the decompressing chamber 21 through the gap spaces formed between the protuberances or recesses of the valve 37 and the inner periphery of the valve chamber 35 when it is displaced downwardly away from the terminal open end 38 of the second high pressure passage 23. The lower end of the valve 37 is abutted against an L-shaped lever 41 which is pivotally supported on a pin 39 fixed in the low pressure casing 16. This L-shaped lever 41 is connected to a shaft 45 which transmits the displacement of a diaphragm 43 which defines the decompressing chamber 21 together with the low pressure casing 16. The shaft 45 is fixed by a nut 49 to shells 47 a and 47b which grip the diaphragm 43. Designated at 51 is a spring member which is interposed between the outer shell 47a and a cover 53 which is fixed to the low pressure casing 16 through the diaphragm 43 and provided with a hole opening to the atmosphere. The spring constant of this spring member is determined depending upon the desired fuel gas pressure after the pressure reduction.
When the pressure in the reducing chamber 21 is low and the diaphragm 43 is displaced rightward in the drawing, the valve 37 is held in the lower position, permitting the fuel gas to flow into the decompressing chamber 21 through the second high pressure gas passage 23. As the air pressure in the decompressing chamber 21 gradually increases, the diaphragm 43 is displaced leftward, and the valve 37 closes the terminal open end 38 of the second high pressure passage 23 to block the flow of fuel gas. In this manner, the air pressure in the decompressing chamber 21 is constantly maintained at a level corresponding to the spring force of the spring member 51 at a stationary position of the diaphragm 43, discharging the fuel gas into the low pressure gas passage 55 under that pressure.
On the other hand, the fuel gas undergoes adiabatic expansion as it is released into the decompressing chamber 21, so that the parts neighboring the terminal open end 38 of the second high pressure passage 23 and the valve chamber 35 are cooled to a considerable degree. Therefore, in present embodiment, a PTC heater 15 is provided around the circumference of the second high pressure passage 23 and the valve chamber 35. The PTC heater 15 which is fixedly mounted on the low pressure casing 16 by bolts 63 and 65 includes a heating element 57 consisting of a PTC thermistor of BaTiO 3 type, wires 59 connected to the opposite ends of the heating element 57 to apply a predetermined voltage thereto, and a waterproof cover 61. The voltage application to the heating element 57 may be effected without a special control, for example, linked with the ignition to effect constantly when the engine is in operation. Although the temperature in the neighborhood of the terminal open end 38 drops immediately after starting the engine, the neighboring parts are heated up almost instantly by the large current flowing through the heating element 57 which initially has a small resistance. Once heated up, the resistance of the heating element 57 increases extremely, maintaining the neiborhood of the second high pressure passage 23 and valve chamber 35 at a predetermined normal temperature without a large electric power consumption.
Though the PTC heater 15 is located only around the second high pressure gas passage 23 and valve chamber 35 in this particular embodiment, it should be understood that the present invention covers various modifications or alterations which can be made in this regard, for example, location of the heater in other positions or extension of the heater onto the circumference of the decompressing chamber 21.
Referring now to FIG. 7, there is schematically shown another embodiment of the fuel supply system for gaseous fuel operated vehicle, employing a regulator with a heat pipe. In this case, the regulator is divided into two or more units to shorten the length of the high pressure gas conduit. If it is divided into two units, for example, a primary regulator 1 which is formed integrally with a fuel cutoff valve 9 and a CNG charged bomb 2 are located in a luggage room section in the rear portion of a vehicle (a trunk room of a passenger car or a loading platform of a truck), locating a secondary regulator 4 in an engine room section 6 in a front portion of the vehicle along with a mixer 5 and an engine 10. The primary and secondary regulators 1 and 4 are interconnected by a conduit 8 which is laid across a passenger's room section 7 of the vehicle.
The fuel gas such as CNG which is charged in the fuel bomb 2 under pressure of 150-200 kg/cm 2 in a fresh state is fed to the primary regulator 1 through the fuel cutoff valve 9 to reduce the gas pressure, for example, to 3-5 kg/cm 2 , and then fed to the secondary regulator 4 through the conduit 8. The fuel gas which has undergone the primary pressure reduction is further decompressed by the secondary regulator 4 substantially to the level of the atmospheric pressure, for example, to a level of 0 to 200 mmAq, and supplied to the engine 10 after mixing same with air in a predetermined ratio by the mixer 5 which is formed integrally with or separately from the engine 10. The exhaust gas resulting from combustion of the air-fuel mixture in the engine 10 is cleaned by a catalytic converter 66 before releasing into the atmosphere through an exhaust pipe 67. Illustrated in FIG. 8 is the positional relationship of the various component parts of a vehicle as shown in FIG. 7, a truck in this case. Like component parts are designated by like reference numerals, and their description is omitted here to aboid repetitions.
In this embodiment, the primary regulator 1 is constituted, as shown particularly in FIG. 9, by a high pressure casing 68 which is attached with the fuel cutoff valve 9, a low pressure casing 69 which is provided with various parts for pressure reduction, and a heat pipe 70 which is interposed between the two casings and has its one end extended into the exhaust pipe 67. The high pressure casing 68 interiorly defines a fuel cutoff chamber 71 which is in communication with a first high pressure gas passage 72 connected to a high pressure conduit from the fuel bomb, not shown, and with a second high pressure gas passage 74 communicating through the valve chamber 73 with a pressure reducing chamber (not shown) which is formed in the low pressure casing 69.
The fuel cutoff valve 9 includes a needle valve 74' which is movable up and down in the fuel cutoff chamber 71, and an electromagnetic coil, not shown, for driving the needle valve 74', the cutoff valve 9 being integrally attached to the high pressure casing 68 by fastening means or the like. By making or braking the connection of the electromagnetic coil with a battery, not shown, the needle valve 74' is driven downward in the drawing to abut against a conical wall 75 in a lower portion of the fuel cutoff chamber 71 to block the downward flow of the fuel when the engine is at rest or at the time of emergency.
The low pressure casing 69 is of a known construction using a diaphragm, not shown, and arranged to move up and down a valve 76, which is loosely fitted in the valve chamber 73, according to displacement of the diaphragm thereby opening or closing a clearance between the valve 76 and an annular projection 77 (corresponding to the terminal open end) which is formed on the high pressure casing 68 around the circumference of the opening of the second high pressure gas passage 74 to control the fuel gas flow from the second high pressure gas passage 74 to a decompressing chamber which is formed in the low pressure casing 69 though not shown, while reducing the fuel gas pressure to a predetermined level.
On the other hand, the exhaust manifold 78 of the engine 10 is connected to a catalytic converter 66 through an upstream exhaust pipe 79, and an exhaust pip 67 is connected to the catalytic converter 66. The exhaust gas which is discharged from the respective cylinders of the engine 10 and led to the upstream exhaust pipe 79 through the exhaust manifold 78 is cleaned through the catalytic converter 66 and passed in hot state through the exhaust pipe 67 before release into the atmosphere.
The heat pipe 70 has its one end so arranged as to wrappingly contact the high pressure casing 68 around the circumference of the second high pressure gas passage 74, forming an annular cavity 80 in concentric relation with the second high pressure gas gassage 74. The other end 81 of the heat pipe 70 is protruded into the exhaust pipe 67 through a flange 82 which is formed on the exhaust pip 67. The heat pipe 70 is fixed to the flange 82 by way of a disk-like projection 83 which is formed around the heat pipe 70 and fastened to the flange 82 by a plural number of bolts and nuts 85 through a heat resistant shock absorbing material 84 like rubber of the like.
As seen in FIG. 10 which shows the basic construction, the heat pipe 70 is constituted by a pipe 87 having a wick structure with high capillarity adhered on the inner periphery thereof, and an operating liquid which is sealed in the pipe after evacuation such that the wick is filled with the liquid to a sufficient degree. Accordingly, when one end of the heat pipe is heated while cooling the other end, the operating liquid in a heated zone is evaporated by depriving the heat of vaporization, and the operating liquid in a cold zone condenses by giving up the heat of condensation. As a result, there occurs a pressure difference between the vapor phases in the heated and cooled zones, causing the vapors to flow from the heated zone to the cooled zone through the passage 88 in the pipe 87. On the other hand, the liquid surface in the heated zone sinks into the wick 86 by evaporation of the operating liquid, increasing the capillary pressure, while the capillary pressure in the cooled zone drops due to condensation of the vapors. Consequently, by the difference in capillary pressure between the heated and cooled zones, the operating liquid in the cooled zone is caused to flow toward the heated zone through the wick. In this manner, the vapors resulting from evaporation in the heated zone are condensed in the cooled zone and returned to the heated zone, and the same cycle is repeated. Thus, heat is transferred to the cooled zone by vapors, mainly in the form of latent heat resulting from phase changes by evaporation and condensation, dissipating the heat of condensation to the outside from the cooled zone. Normally, the amount of heat transfer by a heat pipe is about several hundred times that of copper.
In this embodiment, the aforementioned heated zone corresponds to the heat pipe portion which is disposed in the exhaust pipe 67, and the cooled zone corresponds to the circumference of the second high pressure gas passage 74 of the primary regulator 1 and the valve chamber 73. Accordingly, the heat of the exhaust gas which passes through the exhaust pipe 67 is tranferred to the regulator 1 adequately through the heat pipe 70, suppressing the cooling efect of the adiabatic expansion of the fuel gas from the second high pressure gas passage 74 to prevent freezing of fuel gas components.
Although the heat pipe 70 is located only around the circumferences of the second high pressure gas passage 74 and valve chamber 73 in this particular embodiment, it is possible to locate the heat pipe in other positions without departing from the technical sphere of the invention, for example, to extend the heat pipe as far as the circumferences of the fuel cutoff chamber 71 and the decompression chamber in the low pressure casing 69. The other end of the heat pipe 70 which is protruded into the exhaust pipe 67 downstream of the catalytic converter 66 may be instead protruded into the upstream exhaust pipe 79 or the catalytic converter 66 if desired.
It will be appreciated from the foregoing description that, according to the present invention, the fuel gas which flows through the conduit laid in the passenger's room section has already been decompressed to a substantial degree by the upstream regulator, almost completely precluding the possibility of leakage of fuel gas from the conduit. In addition, since the upstream regulator is located in the vicinity of the fuel gas bomb in the luggage room section, the length of the high pressure gas conduit can be shortened to an extent which is desirable for the sake of safety. Namely, should a leak of the high pressure fuel occur, it takes place in the luggage room section of the vehicle and the leaked gas is released into the atmosphere safely without flowing into the passenger's room section or the engine room section from which an inflammable gas should be kept out.
In a case where the fuel cutoff valve is provided between the fuel gas bomb and the upstream regulator, the supply of fuel gas is cut off at a position close to the bomb when the engine is stopped. This minimizes the conduit portion which is constantly subjected to a high pressure, enhancing the reliability and safety further more.
Since the cooling effect of the adiabatic expansion of the decompressed fuel gas on the circumventive parts is precluded by a PTC heater in an embodiment of the regulator according to the invention, it is possible to heat up these parts more promptly immediately after starting an engine and to maintain them at a desired temperature more stably thereafter as compared with the technology of heating the regulator by the use of cooling water heated by the engine. This heat is also transferred to the fuel cutoff valve to prevent freezing thereof.
In case of the regulator employing a heat pipe, an arbitrary portion of the exhaust system can be used as a heat source, so that the temperature of the heated zone can be set at a desired level without providing a special energy source for heating. The intermediate portion between the opposite ends of the heat pipe normally has a heat insulating structure, which has no heating effect on adjacent parts even if located along a steel sheet of the vehicle body or along the fuel gas bomb, and therefore imposes no thermal affect on the gas fuel supply system. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to the field of telecommuting with remote personal computers to access a network file system. Specifically, the present invention pertains to the field of synchronization of local copies of network files on a remote personal computer with the network files on the network file system.
2. Discussion of the Related Art
If the user creates a file on his office PC and modifies it when he gets home, the user must be certain that the file on his office PC is updated with his changes. Keeping files “in sync” ensures that both files are identical and helps prevent loss of data and time.
Conventionally, the computer user having separate home and office personal computers must tediously remember to copy the files upon which he plans to work or needs access to from the office computer to the home computer before working at home and to copy the latest version of the files from his home computer to his office computer after working at home.
A need exists for automating the process of synchronizing home and office computer files without relying upon the computer user's memory of what files he needs or has modified.
SUMMARY OF THE INVENTION
Conventionally, the computer user having separate home and office personal computers must tediously remember to copy the files upon which he plans to work or needs access to from the office computer to the home computer before working at home and to copy the latest version of the files from his home computer to his office computer after working at home.
According to the present invention, when the user works at home on his home computer, a work monitor logs his file activities on all the drives of his home computer in a work monitor log, which can be displayed in a work monitor window. The user can choose to update from the work monitor window. When update is selected, the files in the work monitor log are selected for file synchronization. When file synchronization is performed, files on the user's home computer are synchronized with corresponding files on the user's office computer. Preferably, only files corresponding to file activity during the current day are automatically selected for synchronization in response to the user choosing update from the work monitor window. Preferably, the same path and file name are synchronized on the user's home and office computers, although the user can specify that a file and path name on the home computer corresponds to a different file and path name on the office computer. Preferably, the date and time of a file on the home computer selected for file synchronization are compared to the corresponding date and time of the corresponding file on the office computer to determine the direction of file synchronization. If the version of the file on the home computer is younger than the version of the file on the office computer, then the version on the home computer is written over the version on the office computer. If the version on the office computer is younger than the version on the home computer, then the version on the office computer is written over the version on the home computer.
The file activities which qualify for logging in the work monitor log are selectable by the user as either accesses to the file, for example, reading a file without necessarily writing over it, or as file modification, which requires that the user writes the file. The generation of the work monitor log involves logging each file activity when the work monitor is enabled by the user. The user may wish to disable the work monitor for periods of time for various reasons. The user may select a variable time period for which log entries are maintained in the work monitor log, for example one week. Work monitor log entries are deleted from the work monitor after they have been in the work monitor log for more than the variable time period.
These and other features and advantages of the present invention are described in the Detailed Description of the Invention in conjunction with the Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a general purpose computer system suitable for implementing the methods according to the present invention.
FIG. 2 illustrates the first panel of the Work Monitor Setup Wizard, in which the user specifies if the user wants to log incoming and outgoing faxes and incoming and outgoing phone calls.
FIG. 3 illustrates the second panel of the Work Monitor Setup Wizard, in which the user selects whether or not to monitor accessed or monitored files.
FIG. 4 illustrates the third panel of the Work Monitor Setup Wizard, in which the user selects the number of days that the user wants pcTELECOMMUTE to retain information in the log before automatically deleting it.
FIG. 5 illustrates a File Sync window according to the present invention.
FIG. 6 illustrates a method according to the present invention of logging file names corresponding to file accesses on the home computer if the work monitor is enabled.
FIG. 7 illustrates a method according to the present invention of logging file names corresponding to computer file modifications on the home computer if the work monitor is enabled.
FIG. 8 illustrates the work monitor window according to the present invention.
FIG. 9 illustrates the Work Monitor button on the Telecommute Control Center.
FIG. 10 illustrates a method according to the present invention of deleting any work monitor log entry which has been in the work monitor log for longer than the period specified by the user.
FIG. 11 illustrates the method of processing a work monitor update request according to the present invention.
FIG. 12 illustrates the File Sync window used in the methods according to the present invention.
FIG. 13 illustrates the method of synchronizing the corresponding home and office computer files according to the present invention.
The Figures are thoroughly explained in the context of the invention in the following Detailed Description of the Invention.
DETAILED DESCRIPTION OF THE INVENTION
Conventionally, the computer user having separate home and office personal computers must tediously remember to copy the files upon which he plans to work or needs access to from the office computer to the home computer before working at home and to copy the latest version of the files from his home computer to his office computer after working at home.
If the user creates a file on his office PC and modifies it when he gets home, the user must be certain that the file on his office PC is updated with his changes. Keeping files “in sync” ensures that both files are identical and helps prevent loss of data and time. pcTELECOMMUTE™ (pcTELECOMMUTE is a registered trademark of Symantec Corporation) synchronizes files so that the most recent version is on both his home and office PCs.
Using pcTELECOMMUTE, the user can quickly create a list of files that the user wants to synchronize, and synchronize them all in a single step. pcTELECOMMUTE maintains this list of file synchronizations so that the user can perform them again and again. If the user starts his workday at home by synchronizing his files, the user can be sure that he is working on the most recent version of the file—regardless of whether it was last changed at home or in the office.
If the user modifies a file at home and forgets to synchronize it with his office PC, the pcTELECOMMUTE DayEnd Sync™ (DayEnd Sync is a registered trademark of Symantec Corporation) feature will remind the user to synchronize his files at the end of his workday.
FIG. 1 illustrates a general purpose computer system 100 suitable for implementing the methods according to the present invention. The general purpose computer system 100 includes at least a microprocessor 104 . The general purpose computer may also include random access memory 102 , ROM memory 103 , a keyboard 107 , and a modem 108 . All of the elements of the general purpose computer 100 are optionally tied together by a common bus 101 for transporting data between the various elements. The bus 101 typically includes data, address, and control signals. Although the general purpose computer 100 illustrated in FIG. 1 includes a single data bus 101 which ties together all of the elements of the general purpose computer 100 , there is no requirement that there be a single communication bus 101 which connects the various elements of the general purpose computer 100 . For example, the microprocessor 104 , RAM 102 , and ROM 103 , are alternatively tied together with a data bus while the hard disk 105 , modem 108 , keyboard 107 , display monitor 106 , and network interface 109 are connected together with a second data bus (not shown). In this case, the first data bus 101 and the second data bus (not shown) are linked by a bidirectional bus interface (not shown). Alternatively, some of the elements, such as the microprocessor 102 and RAM 102 are connected to both the first data bus 101 and the second data bus (not shown), and communication between the first and second data bus occurs through the microprocessor 102 and RAM 102 . The network interface 109 provides communication capability to a local area network LAN using an ethernet connection, for example. The modem 108 allows the computer 100 to communicate through the telephone system. The methods of the present invention are executable on any general purpose computer system such as the 100 illustrated in FIG. 1 , but there is clearly no limitation that this computer system is the only one which can execute the methods of the present invention.
Tracking the Workday
The pcTELECOMMUTE Work Monitor keeps track of the work the user does on his home PC including files the user creates, modifies, or accesses; calls the user makes and receives; and faxes the user sends and receives. The user specifies the kinds of files and activities the user wants pcTELECOMMUTE to monitor and how long the user wants the activities to remain in the Work Monitor log. If the user needs to report on the time the user spends working at home, he can print a status report from the Work Monitor.
Upon installing pcTELECOMMUTE on his home PC, the user can choose to set up his home connection, telephone, fax, file synchronization, and Work Monitor, or the user can enter or change this information later after installation.
Setting Up File Synchronization:
In the first panel of the File Sync Setup Wizard, the user can specify if they want to automatically send files to a folder and enter the path for the folder or if the user wants to select a folder each time the user transfers files. Thus, the user selects to automatically send files to a specified folder on the office PC, or selects to manually designate a unique folder for each file transfer and update procedure. Manually designating the folder the user wants is the default choice.
In the second panel of the File Sync Setup Wizard, the user can specify if they want to verify before overwriting a file and if the user wants pcTELECOMMUTE to check for viruses on transferred files. Thus, the user selects to see a warning before overwriting a file if the user wants to confirm overwriting a duplicate file on the office PC. The user unchecks this option to have pcTELECOMMUTE check the date and time on the file and automatically overwrite older files only.
Setting Up the Work Monitor:
In the first panel of the Work Monitor Setup Wizard, the user can specify if they want to log incoming and outgoing faxes and incoming and outgoing phone calls. FIG. 2 illustrates the first panel of the Work Monitor Setup Wizard, in which the user specifies if the user wants to log incoming and outgoing faxes and incoming and outgoing phone calls.
In the second panel of the Work Monitor Setup Wizard, the user can specify if they want to monitor modified files or accessed files. FIG. 3 illustrates the second panel of the Work Monitor Setup Wizard, in which the user selects whether or not to monitor accessed or modified files. The user can select Log Modified Files if the user wants pcTELECOMMUTE to monitor files the user creates or modifies on his home PC. The user can select Log Accessed Files if the user wants pcTELECOMMUTE to monitor files the user accesses or reads, even if the user does not modify the files. In the File Extension Types To Log field, the user can enter the filename extensions that the user wants pcTELECOMMUTE to monitor. The field already contains the filename extensions of several popular Windows applications. If the user wants pcTELECOMMUTE to monitor other file types, the user enters the filename extensions (without a period) in the field. The user must be sure to separate extensions with a comma. The user can also delete any extension listed in the field if the user does not want to monitor it on his home PC.
In the third panel of the Work Monitor Setup Wizard, the user selects the number of days that the user wants pcTELECOMMUTE to retain information in the log before automatically deleting it. FIG. 4 illustrates the third panel of the Work Monitor Setup Wizard, in which the user selects the number of days that the user wants pcTELECOMMUTE to retain information in the log before automatically deleting it.
The Work Monitor can keep entries in its log for up to 30 days before deleting them. For example, if the user wants to keep entries in the log for a week, use the default value of 7. Entries that are older than 7 days are deleted automatically from the log.
Looking at the pcTELECOMMUTE Windows
PcTELECOMMUTE uses three windows to display the user's information in convenient lists. These windows are the Contact List, Inbox, and Work Monitor.
Closing pcTELECOMMUTE
When the user no longer needs to use pcTELECOMMUTE, the user can close it. At the end of his workday at home, the user should close pcTELECOMMUTE so that it can notify the user of files that the user changed on his home PC, but have not yet synchronized with files on his office PC. If the user modified a file on his home PC, but has not synchronized it with his office PC, pcTELECOMMUTE displays the DayEnd Sync dialog box.
If the user wants to synchronize the files that the user modified, the user indicates this in the DayEnd Sync dialog box. PcTELECOMMUTE displays the File Sync window, which lists the files that should be synchronized. FIG. 5 illustrates a File Sync window according to the present invention.
To close pcTELECOMMUTE completely, the user must close the Telecommute Control Center and all open pcTELECOMMUTE windows. Closing the Telecommute Control Center turns off the Work Monitor.
The Work Monitor can keep track of all his phone and fax activities and include them in a status report. Regardless of how the user makes a call, the Work Monitor can record the call information, including its duration, and enter it in the Work Monitor log.
Connecting to his Office PC
When the user connects to his office PC, the user begins what is referred to as a remote control session because the user controls the activities on his office PC remotely from his home PC. The remote control session lasts until the user disconnects from his office PC. Ending a remote control session disconnects his home PC from his office PC.
If the user does not want his office PC to wait for another connection for a remote control session, clear the Host Accepts Another Call option. In general, the user should leave this option set, so that the user can connect to his office PC again for another remote control session. If the user clears this option, the user cannot connect to his office PC for another remote control session, although the user can still perform file transfers using File Sync.
One essential function of successful telecommuting is maintaining the files on his home and office PCs so that they are always up-to-date. If the user creates a file on his office PC and modifies it at home, the user needs to be sure that the changes the user makes are also made in the file on his office PC.
The user can use pcTELECOMMUTE File Sync to quickly send and receive files and to synchronize files between his home and office PCs. In addition, the user can perform many file maintenance tasks, such as copying, renaming, and deleting files and folders using pcTELECOMMUTE File Transfer.
Regardless of the method the user uses to maintain his files, the Work Monitor can keep track of the file activities the user performs so that files the user modifies or accesses on his home PC are synchronized with those on his office PC.
Both pcTELECOMMUTE File Sync and pcTELECOMMUTE File Transfer allow the user to send files to and receive files from his office PC. Each offers the user different advantages, however. Using File Sync, the user can synchronize files on his home and office PCs so that they each contain the most recent copies of files. The user specifies the files the user wants to transfer in an easy-to-use wizard. File Sync maintains a list of file transfers the user specifies so that the user can perform them again and again. If the user is working on a document both at home and in the office over a period of time, File Sync can be used to synchronize the document on both his PCs. The File Sync Wizard is an efficient way to ensure that his files are up-to-date. If the user wants to synchronize files or folders, so that they are identical on his home and office PCs, the user must use File Sync.
The user can also use File Transfer to send and receive files. Because File Transfer displays the files on both his PCs as lists, the user may find it easier to locate and select the files or folders the user wants to transfer. However, File Transfer does not maintain a list of the file transfers the user has performed. If the user wants to perform other maintenance functions, such as copying or deleting files, the user should use File Transfer.
Using File Sync
pcTELECOMMUTE's File Sync allows the user to keep information up to date with his most recent version of files when he works from home. With pcTELECOMMUTE's File Sync the user can synchronize individual files, entire folders or sub-folders on both the home and office PCs. The user can use File Sync to send files to, receive files from, and synchronize files with his office PC or network. When the user sends a file, pcTELECOMMUTE copies the file or folder from his home PC to his office PC or network. If the folder does not exist on his office PC, pcTELECOMMUTE creates it. If a file or folder with the same name and location exists on his office PC, pcTELECOMMUTE can prompt the user before overwriting the file.
When the user receives a file or folder from his office PC, pcTELECOMMUTE copies the file or folder from his office PC to his home PC. When the user synchronizes files, pcTELECOMMUTE copies the file from his office or home PC, depending on which is newer. pcTELECOMMUTE compares the date and time of both files and overwrites the older file with the newer file.
When the user synchronizes folders, pcTELECOMMUTE makes sure that both folders contain the same files. For example, if a file exists in the folder on his home PC, but not on his office PC, pcTELECOMMUTE copies the file to the folder on his office PC. If two files have identical names in the folders, pcTELECOMMUTE copies the newer file, overwriting the older file.
Setting Up his Home PC for File Sync
The user can set up pcTELECOMMUTE on his home PC so that it sends files to a default folder on his office PC, warns the user before overwriting a file, and checks for viruses during a file transfer. If the user sets up his home PC for file transfers when the user installed pcTELECOMMUTE, the user does not have to set it up again unless the user wants to change any options the user specified. If the user did not set it up for file transfers during installation or the user needs to change the setup information, the user can use the File Sync Setup Wizard.
Looking at the File Sync Window
The File Sync window maintains a list of files to be sent to, received from, or synchronized with files on his office PC. Each entry in the File Sync window is actually a command, which shows the type of transfer (Send, Receive, or Sync), the name and path of the files or folders on his home PC and his office PC, and for folders, an indication if files in subfolders are to be transferred also.
If the user has already specified a file transfer using the File Sync Wizard, the command for that transfer appears in the window. (The files are not transferred until the user clicks the Start button in the File Sync window.) The user can add additional commands for transfers and perform them directly from this window.
Creating his First File Transfer Command
Generally, the user adds file transfer commands to the File Sync window by clicking the File Sync button on the Telecommute Control Center. The first time the user clicks the File Sync button, the File Sync Wizard appears to help the user create the command. After the user has added his first file transfer command, each time the user clicks the File Sync button, the File Sync window appears. The user can then add file transfer commands by clicking the New button in the window.
To create his first file transfer command, on the Telecommute Control Center, the user clicks the File Sync button. The File Sync Wizard appears. The user chooses one of the following from the Action list: Synchronize, Send, and Receive.
Synchronize Synchronize files or folders on his home and office PCs
Send Copy a file or folder from his home PC to his office PC
Receive Copy a file or folder from his office PC to his home PC
The user chooses one of the following from the Type list: File and Folder. If the user is sending, receiving, or synchronizing the contents of a folder, select the Include Subfolders option if the user wants to transfer all files in all subfolders.
The second panel of the File Sync Wizard appears. The user types the filename or folder name and full path of the file or folder on the home PC to be used in the transfer, or clicks the Browse button to locate the file or folder. If the user is specifying a synchronization, the filename must be the same on both the home and office PCs. The user can copy the file or folder name in the Home Selection field and paste it into the Office Selection field in the next wizard panel.
The third panel of the File Sync Wizard appears. If the user copied the name of the file or folder in the second panel of the wizard, right-click in the Office. Type the filename or folder name and full path in the Office Selection field. Alternatively, the user can click the Browse button to locate the file or folder on his office PC or his office network. If the user has not yet connected to his office PC, pcTELECOMMUTE asks if the user wants to connect now, the user should indicate that he should connect now. The Browse for Office Folder or Browse for Office File dialog box appears. The user then locates the folder or file and clicks Select. The third panel of the wizard reappears, displaying the name of the file or folder the user selected. The user clicks Finish. The File Sync window appears and displays the file transfer command.
Adding File Transfer Commands
After creating the first file transfer command, the user can add more commands to the File Sync window to specify additional files or folders the user wants to transfer or synchronize. To add a file transfer command in the File Sync window: In the File Sync window, the user clicks the New button or chooses New from the File menu. The first panel of the File Sync Wizard appears. The user follows the instructions in the panels. The user can quickly add a command to the File Sync window by dragging a file to the window. For example, the user can select the file in Windows Explorer and drag it to the File Sync window. pcTELECOMMUTE adds the filename and path to the File Sync window. If this is the first time the user has transferred the file, the user must modify the command to specify the file on the office PC. If the user drags the same file to the File Sync window again, pcTELECOMMUTE automatically enters the office PC filename that the user specified previously in the Office Selection column of the window.
To add a file transfer command by dragging a file, the user drags the file to the File Sync window. pcTELECOMMUTE adds the filename to the File Sync window. If this is the first time the user has transferred this file, the user must complete the command. If the user has transferred this file before, pcTELECOMMUTE enters the previous office PC filename in the Office Selection column. The user can modify the command, if necessary. The user then right-clicks the command and chooses Modify from the shortcut menu. The user enters or changes the file transfer information to complete the command.
If the user wants to add a file transfer command that is similar to an existing file transfer command, the user can duplicate the existing command. Then, in the File Sync Wizard, the user can change any part of the command. For example, if the user has added a command to send all files in the C:\JuneReports folder to his office PC and later want to send all files in the C:\JulyReports folder, the user can duplicate the command and, in the File Sync Wizard, edit the folder name. To add a file transfer command that is based on another command, the user selects the command in the File Sync window. From the Edit menu, the user chooses Duplicate. After the File Sync Wizard appears, the user makes any required changes in the File Sync Wizard.
Changing File Transfer Commands
After the user has added a file transfer command to the File Sync window, the user can change it using the File Sync Wizard. To change a file transfer command, in the File Sync window, the user does either of the following: Select the file transfer command that the user wants to change and click the Modify button in the toolbar, or double-click the file transfer command that the user wants to change. The first panel of the File Sync Wizard then appears.
The user may change the order of file transfer commands. File transfer commands are performed in the order in which they appear in the File Sync window. The user can change the order of commands in the window. The user might want to change the order of commands, for example, so that all commands that access the same drive on his office PC or on a network server appear together in the list.
To change the order of commands in the File Sync window, the user, in the File Sync window, selects the file transfer command that the user wants to move. The user then clicks the Move Up or Move Down Button in the toolbar.
Deleting File Transfer Commands
If the user finds that the user no longer needs a file transfer command, the user can permanently delete it from the File Sync window. Deleting a file transfer command from the File Sync window cannot be undone. If the user inadvertently deletes a command, the user must re-enter the file transfer information using the File Sync Wizard.
To delete one or more file transfer commands from the File Sync window, in the File Sync window, the user selects the commands that the user wants to delete. The user shift-clicks to select multiple commands that are adjacent in the list. The user ctrl-clicks to select multiple commands that are dispersed in the list. Then the user either clicks the Delete button in the toolbar, presses the delete key on the keyboard, or right-clicks and chooses Delete from the shortcut menu. At the confirmation message, the user clicks yes. The selected file transfer commands are deleted from the File Sync window.
Transferring the Files
Adding a file transfer command to the File Sync window does not actually transfer files; it simply shows a command that the user wants to perform at some time. The user performs the file transfers directly from the File Sync window.
To transfer files, in the File Sync window, the user clicks the Start button. If the user has not connected to his office computer, pcTELECOMMUTE asks if the user would like to connect now.
If the user selected the Verify Before Overwriting option in the File Sync Setup Wizard and a file on his home PC has the same name as one on his office PC, the user may overwrite the file, overwrite all files in the transfer, or not overwrite the file, in which case the file transfer is not performed for that file. The user may click Cancel to cancel all file transfers. If the user chose Yes or Yes To All, pcTELECOMMUTE transfers the file or files and displays the Transfer Progress dialog box.
If the user wants to disconnect from his office PC, the user selects Disconnect When Finished before the transfer is complete.
Maintaining Files with File Transfer
Using pcTELECOMMUTE File Transfer, the user can maintain the files on his home and office PCs from home. The user can transfer files between his home and office PCs as well as copy, rename, and delete files on either PC.
Keeping Track of The User's Home Workday
The pcTELECOMMUTE Work Monitor can keep track of the incoming and outgoing faxes and phone calls as well as files that the user accesses or modifies on his home PC. The Work Monitor log contains a list of his file, phone, and fax activities. From the work monitor icon, the user can view the log of the day's events, including files accessed, files modified, incoming and outgoing calls and faxes sent and received.
FIG. 6 illustrates a method according to the present invention of logging file names corresponding to file accesses on the home computer if the work monitor is enabled. Whenever the home computer determines that a file has been accessed, the method begins at step 601 . If test 602 determines that the work monitor is enabled and if test 603 determines that the user has chosen to log files which are accessed, the filename corresponding to the accessed file is logged in the work monitor log at step 604 . FIG. 7 illustrates a method according to the present invention of logging file names corresponding to computer file modifications on the home computer if the work monitor is enabled. Whenever the home computer determines that a file has been modified, the method begins at step 701 . If test 702 determines that the work monitor is enabled and if test 703 determines that the user has chosen to log files which are modified, the filename corresponding to the modified file is logged in the work monitor log at step 704 .
The user can create a status report from the entries in the Work Monitor log. The user can update, or synchronize, the modified files directly from the Work Monitor window. FIG. 8 illustrates the work monitor window according to the present invention.
Setting Up the Work Monitor
If the user set up the Work Monitor when the user installed pcTELECOMMUTE on his home PC, the user does not need to set it up again unless the user wants to change any options the user selected. During the set up, the user specifies if the user wants the Work Monitor to track incoming and outgoing phone calls and faxes, the files the user wanted monitored, as well as the length of time that the user wants entries to remain in the Work Monitor. If the user did not set up the Work Monitor, or if the user wants to change the Work Monitor set up information, the user uses the Work Monitor Setup Wizard.
Turning the Work Monitor Off and On
When the user starts pcTELECOMMUTE, the Work Monitor is active and begins recording his activities. At times, however, the user may prefer to turn the Monitor off so that it does not record his activities. For example, if the user is ending his workday at home, but will continue to work on his PC for personal activities, the user turns off the Work Monitor. When the Work Monitor is active, a green dot appears on its button on the Telecommute Control Center. Selecting “Monitor” turns the Work Monitor on. A green dot displays above the Work Monitor icon on the Telecommute Control Center to alert the user that it has been activated.
To turn the Work Monitor off or on, on the Telecommute Control Center, the user clicks the down arrow next to the Work Monitor button and chooses Monitor. The checkmark disappears. To turn the Work Monitor on again, the user click the down arrow and choose Monitor again. FIG. 9 illustrates the Work Monitor button on the Telecommute Control Center. Closing the Telecommute Control Center also turns off the Work Monitor.
Viewing the Work Monitor Log
All activities that the user selected for monitoring during Work Monitor setup are kept in the Work Monitor log. The user views the log in the Work Monitor window. To view the Work Monitor window, On the Telecommute Control Center, the user clicks on the Work Monitor button, and the Work Monitor window appears.
Deleting Entries from the Work Monitor
The Work Monitor automatically deletes entries that have been in its log for the length of time that the user set in the Work Monitor Setup Wizard. FIG. 10 illustrates a method according to the present invention of deleting any work monitor log entry which has been in the work monitor log for longer than the period specified by the user. If the home computer determines that any work monitor log entry is older than the user-selected time period, the method begins at step 1001 . The home computer deletes the old work monitor log entry from the work monitor log at step 1002 . The user can also delete any entries from the Work Monitor. For example, the user may want to delete personal phone calls from the Work Monitor before creating a status report.
To delete entries from the Work Monitor, in the Work Monitor window, the user may select multiple entries that are adjacent in the list (Shift-click), select multiple entries that are dispersed in the list (Ctrl-click), or select all entries in the Work Monitor window by choosing Select All from the File menu. Then the user may Click the Delete button in the toolbar, Press the Delete key on the keyboard, or Right-click and choose Delete from the shortcut menu. At the confirmation message, the user clicks yes. The selected entry or entries are permanently deleted from the Work Monitor.
Updating Files from the Work Monitor
If the user has modified a file on his home PC, but not synchronized it with a file on his office PC, the user can update it directly from the Work Monitor. To update a file from the Work Monitor, the user selects the file or files to be updated and clicks the Update button on the toolbar. When the user selects Update from the Work Monitor's toolbar, all the files he has modified throughout the day are selected for File Sync. FIG. 11 illustrates the method of processing a work monitor update request according to the present invention. When the user selects update from the work monitor at step 1101 , all files that have been modified during the current day are selected for file synchronization at step 1102 .
If the user has transferred this file before, the File Sync window appears with the file transfer command entered for this file. The Office Selection column shows the filename that the user specified the last time the user transferred this file. FIG. 12 illustrates the File Sync window used in the methods according to the present invention.
If the user has not transferred the file before, the Office Selection column is blank for this file. pcTELECOMMUTE displays a message informing the user that the user must specify a destination file or folder on his office PC. After clicking OK in the message dialog box, the File Sync Wizard appears so that the user can complete the file transfer command. In the third panel of the File Sync Wizard, the user types the filename and path of the file or folder on his office PC or clicks the Browse button to connect to his office PC so that the user can select a file. Then the File Sync window reappears. In the File Sync window, the user clicks the Start button on the toolbar to update the file.
FIG. 13 illustrates the method 1300 of synchronizing the corresponding home and office computer files according to the present invention. The method 1300 is carried out for each file selected for synchronization in the work monitor. The method begins at step 1301 with the determination that a file in the work monitor is selected for synchronization. The home computer compares the date and time of the home file to the date and time of the corresponding office file at step 1302 . If test 1303 determines that the home file is newer than the office file, then step 1304 overwrites the home file with the office file. If test 1303 determines that the home file is older than the office file, then step 1305 overwrites the office file with the home file.
Although the present invention has been described with respect to its preferred embodiment, that embodiment is offered by way of example, not by way of limitation. It is to be understood that various additions and modifications can be made without departing from the spirit and scope of the present invention. Accordingly, all such additions and modifications are deemed to lie with the spirit and scope of the present invention as set out in the appended claims. | 4y
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BACKGROUND OF THE INVENTION
[0001] In 2003, a new virus called Severe Acute Respiratory Syndrome (SARS) virus was spread from China to many countries in the world. Since it is a new developed virus, no vaccine or medicine is available to cure or treat such a virus. So, people are educated to wear masks, to clean hands frequently and to disinfect the public areas. The door handles in a public area, such as: a department store, a theater, a restaurant, etc., are required to be disinfected by spraying disinfectant thereto. However, such a disinfection work always requires cleaner's hard work and may increase financial burden for the relevant enterprises.
[0002] A conventional door handle is not provided with a fire alarm, a gas detector and a burglar alarm, thereby lacking of safety and security function. In case of fire in a large public place such as a department store, people are panic trying to escape and can not easily distinguish the initial fire location as smoke is spreading and blurring the vision. If the door handle were provided with a fire alarm or warning device thereon, it will indicate the people or the firemen about the fire location to guide a reliable way for escape or for fire fighting.
[0003] The present inventor has found these phenomena and invented the present door handle having multiple functions.
SUMMARY OF THE INVENTION
[0004] The object of the present invention is to provide a door handle including a disinfection device provided in the handle for automatically or manually spraying disinfectant onto the surface of the handle in order to kill micro-organisms existing on the handle for preventing the infection of SARS virus or other pollutants.
[0005] Another object of the present invention is to further provide a fire alarm, a gas detector and a burglar alarm on (or in) the door handle for warning people of a fire, a gas leakage and a burglar intrusion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a sectional drawing of the present invention.
[0007] [0007]FIG. 2 is a top view illustration of the door handle of the present invention.
[0008] [0008]FIG. 3 is an illustration showing the disinfection device as mounted on a door.
[0009] [0009]FIG. 4 is a sectional drawing of another preferred embodiment of the present invention.
DETAILED DESCRIPTION
[0010] As shown in the drawing figures, the multiple-function door handle apparatus of the present invention comprises: a door handle 1 rotatably mounted on a door D, a disinfection means 2 formed in the door handle 1 and in the door D; a fire alarm means 3 , a gas alarm means 4 and a burglar alarm means 5 respectively formed in the door handle 1 ; and a decorative piece 6 embedded or secured in an opening 14 in the door handle 1 having planar or three-dimensional decorative feature 61 formed on the decorative piece 6 . The decorative piece 6 is preferably made of transparent materials.
[0011] The door handle 1 includes an adapter 11 rotatably mounted on a door, a cabinet, a wardrobe or a container. The door handle 1 may be made of metal or any other fire-retarding materials, not limited in the present invention. The shapes of the handle 1 are not limited. An interior 10 in the handle 1 is provided to install the disinfection means 2 , the fire alarm means 3 , the gas alarm means 4 and the burglar alarm means 5 in the interior 10 .
[0012] The disinfection means 2 includes: a disinfectant supplier 20 which may be mounted in a door D (or in a room) as shown in FIG. 3 for outwardly supplying disinfectant from the supplier 20 ; a spray nozzle 22 formed in the handle 1 and fluidically communicated with the disinfectant supplier 20 by a conduit 21 ; a plurality of spray holes 23 formed through the nozzle 22 and the door handle 1 for spraying the disinfectant outwardly to a surface portion 12 of the door handle 1 for disinfecting the handle 1 ; a sensor 24 formed on the door (or on the handle 1 ) for sensing a door opener when depressing the door handle 1 to open the door; and a valve 25 formed on the conduit 21 and operatively opened when the handle 1 is depressed and sensed by the sensor 24 for delivering the disinfectant to be sprayed onto the handle 1 .
[0013] The spray holes 23 are fluidically communicated with a plurality of shallow grooves 121 longitudinally recessed in the surface portion 12 of the door handle 1 so that the disinfectant may be evenly distributed to the surface of the handle 1 through such grooves 121 .
[0014] The surface portion of the handle 1 may be formed as porous structure by powder metallurgy to homogeneously distribute the disinfectant on the surface of the handle 1 .
[0015] The sensor 24 may also be modified as an actuator to be manually actuated for opening the valve 25 for delivering the disinfectant onto the handle surface 12 .
[0016] An automatic spraying system may also be provided for periodically opening the valve 25 for disinfecting the handle 1 .
[0017] The sensor 24 may be a photo sensor such as operated by infrared rays; or a mechanical sensor, not limited in the present invention.
[0018] A boosting pump (not shown) is provided in the disinfectant supplier 20 for pumping the disinfectant outwardly with a sufficient pressure to be sprayed onto the handle surface.
[0019] City (utility) power or battery power may be provided for powering the electric or electronic elements of the present invention. The disinfectant supplier 20 may be modified as a general supply system installed in a control room or center.
[0020] Since the door handle 1 is disinfected automatically or manually in accordance with the present invention, the SARS virus or other micro-organism may be killed or disinfected to prevent from the spreading of SARS or the like, thereby being beneficial for public hygiene. For the multiple functions of the door handle in accordance with the present invention, further alarm devices as provided in the handle 1 are described hereinafter:
[0021] The fire alarm means 3 includes: a temperature sensor or smoke detector (or sensor) for sensing a high temperature or smoke as occurring in a fire accident; and an alarm operatively actuated by the sensor for warning the fire accident. The alarm includes: an optical (or photo) alarm L such as made of LEDs (light emitting diodes); a buzzer B; and a wireless alarm R which may be remotely communicated to a control center, a police station, a fire brigade, or an owner's headquarter. The optical (or photo) alarm L may indicate the fire location which may guide the firemen for an efficient to-the-point fire fighting and also for guiding the people for a safe escape or evacuation.
[0022] The temperature sensor of the above-mentioned fire alarm means 3 may include wax formed on a circuit breaker of the alarm circuit, whereby upon heating by a fire, the wax will be melted to break the circuit to actuate the fire alarm. Many modifications may be made in accordance with the present invention.
[0023] The gas alarm means 4 includes: a gas leakage detector (or sensor) installed in the handle 1 to sense leaking flammable or poisonous gas through perforations 13 formed through the handle 1 ; and an alarm, such as the aforementioned LED (L), buzzer (B) or wireless alarm (R), operatively actuated by the detector for warning the leakage of a hazardous or flammable gas in the surrounding.
[0024] The burglar alarm means 5 includes: an intrusion sensor which may be a vibration sensor or other suitable sensors for sensing an intruder such as a thief or robber when trying to open the door by depressing the door handle 14 ; and an alarm including LED (L), buzzer (B) and wireless alarm (R) operatively actuated by the intrusion sensor for warning an intrusion by the intruder (thief or robber). The alarm may be remotely connected to a police station in order to call for police.
[0025] By the way, a fire, a gas leakage or an intrusion accident may be sensed for actuating an alarm for warning the relevant people for enhancing their safety and security.
[0026] The door handle 1 further includes: the decorative piece 6 made of transparent material (such as glass, or crystal) embedded or formed in a front or upper portion of the handle 1 ; with the transparent decorative piece playing double roles both for decorative purpose and also for transmitting the optical alarm of LED (L) formed in the handle 1 through the transparent decorative piece 6 . The optical alarm of LED can be a flashing light for a remarkable warning.
[0027] A light converging or diverging lens 62 having diamond-like structure may be disposed about each LED (L) of the alarm means to increase the brilliant visual or ornamental effect of the present invention.
[0028] The present invention may be modified without departing from the spirit and scope of the present invention.
[0029] As shown in FIG. 4, an ultra-violet (UV) lamp 7 is provided in the door handle 1 for emitting ultra-violet rays outwardly through a plurality of windows 15 formed through the handle 1 for killing hazardous bacteria or virus on the handle. | 4y
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FIELD OF THE INVENTION
The invention relates to a radial ply tire for a vehicle wheel of the kind comprising a torus-shaped body of elastomeric material having a tread portion, and a belt-shaped reinforcing insert arranged in the body, the reinforcing insert including, in a region radially inwards of the tread of the tire, a reinforcing strip which is adapted to stretch, compress and be pre-loaded in a circumferential direction of the tire, and return, under the influence of internal and external forces.
The strip of the reinforcing insert in such an arrangement forms a strengthener for the lateral stiffness or side stiffness of the elastically pre-loadable belt construction.
BACKGROUND OF THE INVENTION
For tangentially elastic belt constructions of vehicle tires strip-shaped strengtheners are known as so-called transverse belts, which can be pre-shaped radially in a number of planes (EP 0 357 826). These sinusoidal or similarly wavy strips of the transverse belt are, it is true, in a position to perform the desired longitudinal stretching, but they are frequently subject to tears or similar damage on added local deformations of the belts in a radial and lateral direction. Moreover the known wavy strips of the transverse belt take up a relatively large amount of space as they have to be covered over by the rubber matrix over the height of the amplitudes of the waves for mechanical and manufacturing reasons. This has the consequence of involving a relatively large volume of the belt which both adds to cost and also wastes unnecessary energy through internal friction in the body of the belt.
SUMMARY OF THE INVENTION
The invention aims to provide a radial ply tire for a vehicle wheel with a strip-shaped transverse belt serving as a strengthener, which on the one hand achieves adequate transverse stiffness of the tire and on the other hand is sufficiently stretchable, pre-loadable and restorable in the direction of the circumference of the tire without thereby taking up unnecessary space or volume in the body of the tire.
According to the invention, in a radial ply tire for a vehicle wheel of the kind set forth the reinforcing strip includes apertures extending substantially transversely with respect to the circumferential direction of the tire, each aperture extending only partially through the strip, in a transverse direction and the apertures being arranged in rows and offset with respect to one another in successive rows.
This provides a strip which is elastic in a tangential direction and formed in such a way that in a state of equilibrium, that is to say free of stress, it extends virtually in a single plane, that is to say it does not have any waves or other shapes but corresponds in its height to virtually only the thickness of the material.
In contrast to known constructions of such strips or transverse belts which extend radially in several planes in order to provide deformability in a circumferential direction, the strip according to the invention in its unstressed state extends virtually in one plane in the direction of the circumference of the radial ply tire and despite this is still elastic, that is to say stretchable, pre-loadable and compressible, in a tangential direction.
The apertures may be cut-out portions of the strip, extending parallel to one another. The cut-out portions may be slot-like openings extending in a transverse direction with webs remaining between them. The openings are preferably arranged in rows and they can also be arranged offset in succeeding rows so that no circumferentially stiffening cross-section is obtained.
The strip may alternatively be a strip of meandering shape which contains transversely extending cut-out portions extending from its side edges and starting alternately from one side edge and the other, and terminating near the respective opposite side edge.
On the other hand it is also possible to form the strip from at least one compression-resistant and tension-resistant endless filament. Several filaments could be wound around one another to form a cord. The filaments are arranged in the same plane in approximately zig-zag form in such a way that the reversals, for example in arcuate form, of the individual filaments allow at the ends or longitudinal edges of the strip an elastically useful deformation in the tangential direction. An endless strengthener formed in this manner offers the minimum possible resistance to the tangential deformation mechanism of the radial ply tire, which has a particularly advantageous effect on the energy behavior of the tire.
The compression-resistant endless filaments preferably extend almost at right angles to the direction of running of the tire, that is to say laterally and are connected together at the two edges of the transverse belt by respective reversals in direction of almost 180°, but compression-resistant and tension-resistant in both lateral directions. Thereby under the effect of side forces there is obtained a mutual support of the adjacent transverse filaments.
A further advantage of this embodiment is the outstanding radial flexibility which is required for passing over uneven road surfaces. The resulting reduction in the resistance to deformation of the tire in the region of the belt has an advantageous effect on the reduction in the radial and tangential damping action of the tire.
Since, in the above-mentioned embodiments of the strip, it can be arranged to lie in one plane, it can be manufactured from specially shaped steel strip or stiff synthetic resin, or from steel filaments or steel wires. In every case there is achieved a sufficient transverse stiffness of the strip or body serving as the strengthener of the belt.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be further explained in embodiments by way of example illustrated diagrammatically in the accompanying drawing, in which
FIG. 1 is a perspective sectioned partial view of a radial ply tire constructed in accordance with the invention,
FIG. 2 is a plan view of a portion or section of a belt strip of the tire according to one embodiment of the invention,
FIG. 3 is a view similar to FIG. 2 showing a modified embodiment of the belt strip and
FIG. 4 is a view of a further embodiment of the belt strip.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The pneumatic tire or radial ply tire 1 illustrated in FIG. 1 for vehicle wheels, not illustrated further, has a torus-shaped body 2 of elastomeric material with beads 3 formed on it for engaging the wheel, not shown. Embedded in each bead 3 there is a core or wire 4 of inextensible material such as wire rope. Extending within the torus-shaped body from bead to bead is a cord insert 5 which serves as a kind of protection or reinforcement for the rubber material of the torus-shaped body 2.
Within the torus-shaped body 2 and underneath the tread 6 of it there is embedded in the rubber material in addition to a circumferential belt, not shown here, a belt-shaped reinforcing insert 7 which is described in the following in detail in conjunction with three embodiments by way of example illustrated in FIGS. 2, 3 and 4.
In the embodiment according to FIG. 2 the belt-shaped insert 7 comprises a flat strip 8 which can be made of steel or of synthetic resin and extends in the direction of the circumference of the tire 1 as a transverse strip of the belt. This strip 8 contains a multitude of strip-shaped or slot-like openings 9 which extend transverse to the circumferential direction of the tire 1 and thereby of the insert 7. These openings are arranged in successive rows and within these rows they are offset parallel to one another in a transverse direction, as can be seen in FIG. 2.
Between adjacent openings 9 in each row of openings there are webs 10 which separate the openings 9 from one another and which, as a consequence of their zig-zag sequence, hold the strip 8 together as a whole. In this arrangement each web 10 lies opposite an opening 9 of the adjacent row of openings so that elastic extension of the strip 8 in a longitudinal direction or also elastic compression is achieved by the co-operation of the individual openings 9 and the webs 10 lying opposite them.
At the longitudinal edges 11 of the strip 8 there are outwardly open notches 9a in every second row of openings 9 so that also in the region of the side edges or longitudinal edges 11 of the strip 8 the desired elastic extensibility, pre-loadability, restoring action and compression ability of the strip 8 in a longitudinal direction is achieved.
Between the rows of mutually offset openings 9 and 9a there are respective uninterrupted transverse webs 21 which extend from one longitudinal edge 11 of the strip 8 to the other and take care of providing the transverse stiffness of the strip 8.
By matching the material thickness of the strip 8 and the relationship of the dimensions of the openings 9, the webs 10 and the transverse webs 21 there can be set a predetermined progressive tangential spring characteristic of the strip 8 which if necessary makes it possible to do without further tangential spring elements of the belt without adversely affecting the lateral stiffness of the belt and thereby of the radial ply tire 1 as a whole. The spring characteristic of the strip 8 according to FIG. 2 can furthermore be modified by the Shore hardness of the rubber mixture and its coating thickness. Thus, for a given rubber mixture, thin rubber layers engaging the strip 8 on both sides stiffen the spring characteristic of the strip 8 as a consequence of their low deformation clearance whereas thicker layers of the same mixture engaging against the strip lead to a softer spring characteristic. Accordingly, the volume and thereby also the weight of the belt and of the tire as a whole can be significantly reduced.
In the embodiment according to FIG. 3 the strip 8 forming the belt-shaped insert 7 is formed as an endless filament 12 which follows a zig-zag path. At the side edges 11 of the strip 8 there are arcuate reversals of direction 13 which on the one hand take care of providing sufficient lateral stability and on the other hand achieve the elastic stretchability, pre-load ability and restoring action of this particular strip.
In the embodiment according to FIG. 4 the belt-shaped insert 7 is manufactured from a strip-shaped body 14 of stiff synthetic resin or steel. This metal-strip-shaped or foil-shaped strip 14 contains, extending alternately from its side edges 15 and 16, substantially rectangular deep inwards cuts 17 and 18, which overlap one another, so that the strip-shaped body 14 comprises meandering web-shaped portions 19 extending parallel to one another and transversely with respect to the strip 14 and alternating with these there are webs 20 connecting them at one or the other side edge 15 or 16. Accordingly, the strip 14 is capable of stretching and contracting or squeezing together in a longitudinal direction but is laterally stable in a transverse or lateral direction.
In the embodiments according to FIGS. 3 and 4 the filaments 12 (FIG. 3) or the web-shaped portions 19 (FIG. 4) which run in a direction transversely with respect to the strip take care of providing the necessary transverse stiffness of the strip in question. In a most preferred embodiment, the strip has substantially transversely extending stiffening portions having opposed ends, each end of a stiffening portion being joined to a corresponding end of an adjacent stiffening portion, whereby the stiffening portions are joined alternately by the ends.
Preferably, in all the foregoing embodiments the slot-like structured strip is dimensioned, for example by material strength and relationship between width and length of the webs such that under tangential tension loading (through internal pressure in the tire and centrifugal force) of the strip the transversely extending webs lift away somewhat from their flat state and thereby allow bulging respectively between the nodes or webs that connect them together in an offset manner, so that an elastic spring action arises as a result of this deformation of the webs. Therefore the webs alter their angle with respect to the circumferential curvature of the tire under tension loading.
A transverse belt strip of such dimensions is preferably applied to the carcass blank in a stress-free and therefore flat condition with a circumferential length corresponding to 100% of the shaped body (hot mould) so that the transversely extending webs remain flat and therefore free of stress when the tire has been vulcanized.
When a radial ply tire manufactured in such a way as described immediately above and provided with a rate of resistance to or allowable extension of around 101 to 104%, is put under tension loading in operation, it stretches its transversely extending webs in a circumferential direction with a change in angle. In this process the transverse belt strip increases its structural height significantly as a consequence of the radially rising webs. From the flat strip which lies in a single plane there is produced by deformation of the transverse belt under tension a geometrically three-dimensional structure.
When the transverse belt strip structured with slits and deformed under, tension loading in accordance with the invention is subjected radially to a large force as is the case in the supporting surface of the tire by carrying the wheel load, the upstanding transversely extending webs are thereby pressed back from their increased structural height again into their original flat position, whereby however, simultaneously in this loaded portion of the circumference of the belt the elastic stretching of for example 102% to 100% allowed by the alteration in angle previously of the transversely extending webs is mechanically restored.
By this mechanical load-controlled forced return deformation of the transverse belt strip the spring action of the circumferential belt is kinematically extremely effectively assisted.
In the tire as ready for use there result for the slit-shaped structured transverse belt strip according to the invention thereby in the transverse and longitudinal section two geometrically completely independent shapes:
A) In the unloaded periphery the transverse belt strip receives as a consequence of the elastic extension caused by the tension load a radially increased structural height through the alteration in angle of the webs. This geometrical alteration acts significantly on the inherent oscillation behavior of the belt, which suppresses premature occurrence of resonance nodes (standing waves).
B) In the loaded state the radially acting wheel load forces the mechanical kinematic shortening of the transverse belt strip back-into the original flat structural height.
In this flat state the slot-shaped structured transverse belt strip can also very easily match itself to all unevenesses which occur in the ground by local bending actions (within the composite structure).
Therefore in the unstressed state the transverse belt strip extends flat in one plane and alters itself under tension load, in modified embodiments, by increasing the web angle radially in its structural height, that is three-dimensionally, and can thereby stretch elastically. In the elastically stretched state of the strip the webs are deformed back by radial loading again flat into the original plane, whereby the circumferential stretching is kinematically forcibly restored. The transverse belt strip is incorporated in the tire blank in its flat condition with a circumferential length which is about 100% with reference to the dimension of the shape of the tire press and under operating conditions it can stretch elastically up to 105%. In operation the structural height of the belt strip alters between the loaded and unloaded circumference and thereby its longitudinal section.
In a preferred embodiment, the strip is adapted to stretch by up to about 4% in a circumferential direction from a stress-free rest condition. In a most preferred embodiment, the strip is adapted to stretch by up to about 2% in a circumferential direction from a stress-free rest condition. | 4y
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RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application Ser. No. 08/516,050 filed on Aug. 17, 1995 and entitled Electronic Adjustable Pedal Assembly which is a continuation-in-part of U.S. patent application Ser. No. 08/513,017 filed on Aug. 9, 1995, now U.S. Pat. No. 5,632,183 and entitled Adjustable Pedal Assembly.
BACKGROUND OF THE INVENTION
This invention relates to control pedal apparatuses and more particularly to adjustment means for selectively adjusting the position of one or more of the control pedals of a motor vehicle.
In a conventional automotive vehicle pedals are provided for controlling brakes and engine throttle. If the vehicle has a manual transmission a clutch pedal is also provided. These pedals are foot operated by the driver. In order for the driver to maintain the most advantageous position for working these control pedals the vehicle front seat is usually slidably mounted on a seat track with means for securing the seat along the track in a plurality of adjustment positions.
The adjustment provided by moving the seat along the seat track does not accommodate all vehicle operators due to differences in anatomical dimensions. Further, there is growing concern that the use of seat tracks, and especially long seat tracks, constitutes a safety hazard in that the seat may pull loose from the track during an accident with resultant injuries to the driver and/or passengers. Further, the use of seat tracks to adjust the seat position has the effect of positioning shorter operators extremely close to the steering wheel where they are susceptible in an accident to injury from the steering wheel or from an exploding air bag. It is therefore desirable to either eliminate the seat track entirely or shorten the seat track to an extent that it will be strong enough to retain the seat during an impact. Shortening or eliminating the seat track requires that means be provided to selectively move the various control pedals to accommodate various size drivers.
Various proposals were made over a period of many years to provide selective adjustment of the pedal positions to accommodate various size drivers but none of these proposals met with any significant commercial acceptance since the proposed mechanisms were unduly complex and expensive and/or were extremely difficult to operate and/or accomplished the required pedal adjustment only at the expense of altering other critical dimensional relationships as between the driver and the various pedals. Recently a control pedal mechanism has been developed which is simple and inexpensive and easy to operate and that accomplishes the required pedal adjustment without altering further critical dimensional relationships as between the driver and the various pedals. This control pedal mechanism is disclosed in U.S. Pat. Nos. 4,875,385; 4,989,474 and 5,078,024 all assigned to the assignee of the present application. The present invention represents further improvements in adjustable control pedal design and specifically relates to an adjustable control pedal apparatus which is compatible with, and incorporates, a drive-by-wire arrangement in which the link between the pedal and the associated controlled device of the motor vehicle comprises an electronic signal rather than a mechanical linkage.
SUMMARY OF THE INVENTION
This invention is directed to the provision of a simple, inexpensive and effective apparatus for adjusting the control pedals of a motor vehicle.
More specifically, this invention is directed to the provision of an adjustable control pedal apparatus that is especially suitable for use in conjunction with a drive-by-wire throttle control.
The invention apparatus is adapted to be mounted on the body structure of the motor vehicle and includes a carrier, guide means mounting the carrier for fore and aft movement relative to the body structure, drive means operative to move the carrier along the guide means, and generator means operative in response to movement of the pedal structure relative to the carrier to generate an electric control signal proportioned to the extent of movement of the pedal relative to the carrier.
According to the invention, the pedal assembly further includes a coil spring arranged to be torsionally tightened in response to a force applied to the pedal pad, whereby to provide a spring resistance force opposing the pedal apply force, and arranged to be torsionally relaxed in response to release of the pedal apply force, whereby to provide a spring return force, and the pedal assembly further includes means operative in response to torsional tightening of the spring to generate a frictional resistance force that is additive with respect to the spring resistance force and subtractive with respect to the spring return force. This arrangement provides an effective means of providing the desired feel or feedback to the operator upon movement of the pedal and further provides the desired hysteresis effect.
According to a further feature of the invention, the operative means includes an annular sleeve mounted on an annular friction surface and the coil spring closely encircles the sleeve so that the torsional tightening of the spring urges the sleeve into frictional engagement with the friction surface. This specific sleeve and spring construction provides a simple and effective means of providing desired hysteresis effect.
According to a further feature of the invention, the pedal structure includes a pedal arm carrying the pedal pad at the lower end of the pedal arm and a pivot shaft at the upper end of the pedal arm mounting the pedal arm for pivotal movement on the carrier; the carrier includes a housing defining a hub structure defining the annular friction surface; the pivot shaft is journaled in the housing and is positioned concentrically within the hub structure; the sleeve is positioned over the hub structure; and the coil spring winds around the sleeve with one end of the spring anchored to the pedal arm and the other end of the spring anchored to the housing. This specific construction provides a compact package suitable for use in the close confines of the area beneath the instrument panel of a motor vehicle.
According to a further feature of the invention, the generator means comprises a potentiometer whose setting is varied in response to rotary movement of the pivot shaft of the pedal structure. The use of the pivot shaft of the pedal structure as an input shaft for the potentiometer further simplifies and compacts the pedal assembly structure.
In the disclosed embodiment of the invention, the pivot shaft includes a first end portion at one side of the pedal arm and a second end portion at another side of the pedal arm; the first end portion of the pivot shaft is positioned within the housing hub structure; and the second end portion of the pivot shaft comprises an input shaft for the potentiometer.
According to a further feature of the invention, the guide means comprises a guide rod; the carrier includes an upper portion mounted on the guide rod for sliding fore and aft movement along the guide rod; and the pedal structure includes a pedal arm having an upper end mounted on a lower portion of the carrier. This specific guide rod/carrier construction provides a simple and efficient means of providing the desired fore and aft movement of the carrier along the guide rod.
According to a further feature of the invention the guide rod comprises a hollow rod; the carrier further includes a nut slidably positioned within the hollow of the guide rod and means connecting the nut to the carrier so that sliding movement of the nut within the guide rod moves the carrier fore and aft along the guide rod; and the drive means includes a screw shaft threadably received in the nut and means operative to rotate the screw shaft. This specific construction provides an effective drive means for the carrier.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevational view of an accelerator pedal assembly according to the invention;
FIG. 2 is a rear view of the accelerator pedal assembly;
FIG. 3 is a partially exploded view of the accelerator pedal assembly;
FIG. 4 is a perspective view of a sub assembly of the accelerator pedal assembly;
FIGS. 5 and 6 are cross-sectional views of the accelerator pedal assembly;
FIG. 7 is a detail view of a section of a housing employed in the accelerator pedal assembly; and
FIGS. 8, 9 and 10 are schematic views illustrating the manner in which the invention accelerator pedal assembly operates to generate a hysteresis effect.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention accelerator pedal assembly 10, broadly considered, is intended to allow efficient fore and aft movement of the pedal assembly to accommodate operators of varying anatomical dimension and is operative to generate an electronic or drive-by-wire signal in response to pivotal movement of the pedal assembly while retaining the same ergometric operation of the pedal irrespective of the position of adjustment of the pedal.
Pedal assembly 10 includes a mounting bracket 11, a guide structure 12, a carrier assembly 13, a drive assembly 14, a pedal assembly 16, a resistance assembly 18, and a generator means 20.
Mounting bracket 11 is adapted to be suitably secured to the dash panel 22 of the associated motor vehicle, utilizing suitable fastener means, in known manner.
Guide structure 12 includes a transmission housing portion 12a and a guide rod portion 12b. Transmission housing portion 12a is suitably secured to and extends rearwardly from bracket 11 and has a generally cubicle configuration defining an axial bore 12c opening at the front face 12d of the housing portion and further defining a central bore 12e in a rear wall 12f of the housing portion concentric with bore 12c.
Guide rod portion 12b extends rigidly rearwardly from the rear wall 12f of the transmission housing portion, is hollow so as to provide a tubular configuration defining a central circular axial bore 129 concentric with bores 12c and 12e, is open at its rear end 12h, and includes an upper axial slot 12i extending from a location proximate the transmission housing wall 12f to a location proximate guide rod rear end 12h.
Carrier assembly 13 includes a housing 24, a nut 26, a bushing 27, and a key 28.
Housing 24 is designed to move slidably along the guide rod portion 12b of guide structure 12 and preferably is formed of left and right molded acetal plastic sections 30 and 32 which are suitably joined together along a vertical plane by the use of fasteners, heat sealing or other means.
Left housing section 30 includes an upper portion 30a defining a through axial bore 30b and a lower portion 30c defining an annular hub structure 30d and an annular spring chamber 30e in concentric surrounding relation to hub structure 30d and including a tail portion 30f.
Housing 24 is mounted on the guide rod portion 12b of guide structure 12 with bushing 27 positioned in bore 30b and guide rod portion 12b positioned slidably within bushing 27 so as to mount the housing for sliding movement along the guide rod.
Right housing section 32 is generally hollow and includes an outer side wall 32a, a top wall 32b, a front wall 32c, a bottom wall 32d, and an angled rear wall 32e defining an opening 32f.
Nut 26 is circular, preferably plastic, is mounted for sliding movement in circular bore 12g of guide rod 12b, and defines a central threaded bore 26a.
Key 28 is seated at its lower end 28a in a notch or pocket 26b in the upper periphery of nut 26 and passes upwardly through a slot 27a in bushing 27, through guide rod slot 12i, and through an opening 30g in the top wall 30h of left housing section 30 for securement at its upper end 28b, by fasteners 33, to a flange structure 30i upstanding from left housing section top wall 30h. Key 28 thus lockingly interconnects nut 26 and housing 24 so that movement of nut 26 in bore 12g is imparted to housing 24 so as to move housing 24 axially along guide rod portion 12b.
Drive assembly 14 includes a motor 34, a cable 36, a bracket 38, a worm 40, a worm gear 40, and an elongated drive member 42.
Motor 34 comprises a suitable electric motor, with position memory if required, and is suitably secured to dash panel 22 proximate bracket 11.
Cable 36 comprises a well-known Bowden cable and is drivingly secured at one end 36a to the output shaft of motor 34. The other end 36b of cable 36 is drivingly attached to worm gear 40.
Worm gear 40 is suitably journaled in an upwardly angled bore 12j in transmission housing 12a in angled underlying relation to bore 12c.
Drive member 42 includes a front journal portion 42a, a worm wheel 42b, and a rear screw shaft portion 42c. Drive member 42 is positioned within guide structure 12 with journal portion 42a journaled in a retainer 44 positioned in a counterbore 12k in the front end of transmission housing 12a, worm wheel 42b drivingly engaging worm gear 40, and screw shaft 42c extending rearwardly through bore 12e and centrally within guide rod structure 12b for threaded engagement with the threaded central bore 26a of nut 26. It will be seen that actuation of motor 34 has the effect of rotating screw shaft 42c to thereby move nut 26 and housing 24 fore and aft along guide rod 12b with the extent of forward and rearward movement defined and limited by engagement of key 28 with the front and rear ends of slot 12i.
Pedal assembly 16 includes a pedal arm 46, a pedal pad 48 secured to the lower end 46a of the pedal arm, and a pivot shaft 50. Pedal arm 46 passes upwardly through a slot 51 defined in housing 24 at the lower juncture of left and right housing sections 30 and 32. Pivot shaft 50 is fixedly secured to the upper end 46b of the pedal arm and includes a left portion 50a journaled in an aperture 30g in the outboard face of left housing section 30 concentrically within hub structure 30d and a right portion 50b journaled in side wall 32a of right housing section 32 utilizing a bushing 52.
Resistance assembly 18 includes the hub portion 30d of left housing section 30 and further includes a coil spring 54 and a sleeve 56. Resistance assembly 18 is intended to provide feedback or "feel" to the operator to replace the feedback normally provided by the mechanical linkage interconnecting the accelerator pedal and the fuel throttle. With a mechanical linkage, the pedal pressure required when advancing the accelerator pedal is greater than that required to maintain a fixed position. This difference is often referred to as due to the hysteresis effect. This effect is important in maintaining the accelerator pedal in position while driving at a relatively constant speed and it must also be considered in achieving a desired deceleration time. The pressure which must be applied in accelerating is easily borne but if the back pressure of an accelerator spring produced the same effect during the time it was required to retain or maintain speed it would soon become uncomfortable for the operator to maintain a relatively constant speed. The hysteresis effect provides relief. It lessens the load required to maintain a setting of the accelerator yet there is still force to cause reverse pedal action when the foot applied pressure is removed. Resistance assembly 18 provides the "feel" of a mechanical linkage including the desired hysteresis effect to relieve operator fatigue.
Sleeve 56 may be formed, for example, of a Delrin® plastic material and is positioned with a friction fit over hub structure 30d to define an annular plastic-to-plastic frictional interface 57.
Spring 54 comprises a helical spring and is preferably formed of a suitable ferrous material. Spring 54, in addition to the primary convolutions 54a, includes a pedal tail portion 50b and a housing tail portion 50c. Spring 54 is positioned in spring chamber 30e with the primary convolutions 54a in tight, surrounding relation to sleeve 56, pedal tail portion 54 engaging a tab 46c struck from pedal arm 46, and housing tail portion 54c positioned in the tail portion 30f of spring chamber 30e.
Generator means 20 comprises a potentiometer 60 positioned within the hollow of right housing section 32 and suitably secured to housing side wall 32a. Potentiometer 60 includes a central shaft, constituted by pivot shaft portion 50b, a housing 60a concentric with shaft portion 50b, a plurality of resistance elements 60b mounted circumferentially around the inner periphery of housing 60a in side-by-side relation, a wiper arm 60c mounted on shaft portion 50b and operative to electrically slidably engage the resistance elements 60b in response to pivotal movement of shaft 50, and an outlet 60d projecting rearwardly through opening 32f in right housing rear wall 32e and electrically connected to wiper 60c and resistance elements 60b in a manner such that the electrical signal appearing at the outlet 60d varies in proportion to the extent of pivotal movement of pivot shaft 50. It will be seen that pivotal movement of pedal assembly 16 has the effect of rotating pivot shaft portion 50b and thereby varying the electrical signal appearing at the potentiometer outlet 60d so that the signal appearing at outlet 60d is at all times proportioned to and indicative of the pivotal position of the pedal. It will be understood that electric power is suitably supplied to potentiometer 60 and an electrical conduit 62 is suitably connected to potentiometer outlet 60d and extends to the vehicle function or accessory, such as the vehicle throttle, that is being electrically controlled by the pedal assembly.
In operation, the position of pedal pad 48 relative to the operator is selectively adjusted by selectively energizing motor 34 to selectively move nut 26 forwardly and rearwardly within guide rod bore 12g and thereby, via key 28, move the pedal assembly selectively forwardly and rearwardly along guide rod 12b with the limit of forward and rearward movement determined by engagement of key 28 with the respective forward and rearward ends of slot 12i. In any position of adjustment of the pedal, actuation of the pedal or release of the pedal results, in the manner previously described, in the generation of an output signal at the outlet 60d proportioned to the extent of pivotal movement. Since the pivotal movement of the pedal arm is precisely the same in any position of adjustment of the pedal structure, the ergometrics of the assembly do not vary irrespective of the position of adjustment of the pedal assembly and irrespective of the anatomical stature of the operator.
As the pedal is moved downwardly, a "feel" is imparted to the pedal, simulating the feel of a mechanical linkage between the pedal and the controlled vehicle system, by the combined effect of torsioning of the coil spring 54 and frictional sliding or wiping engagement between sleeve 56 and hub structure 30d at frictional interface 57. That is, as force is applied to move the pedal downwardly, the feel imparted is additive and is equal to the combined torsional resistance of spring 54 and the frictional resistance generated at annular interface 57 between sleeve 56 and hub structure 30d. It will be seen that just as the torsional resistance provided by spring 54 increases in proportion to the extent of downwardly pivotal pedal movement, so also does the frictional resistance at interface 57 progressively increase due to the progressively greater squeezing force exerted on sleeve 56 by the progressively tightening spring 54. As the pedal is thereafter released or allowed to return under the impetus of spring 54, the gradually decreasing frictional force at interface 57 becomes subtractive rather than additive with respect to the gradually decreasing torsional spring force, thereby creating the desired hysteresis effect. The amount of feel imparted to the pedal can thus be precisely adjusted by adjusting the spring rate or other parameters of spring 54, and/or by adjusting the materials or other parameters of sleeve 56 and hub structure 20d, thereby rendering it relatively easy to fine tune the system to achieve any desired feel and any desired hysteresis effect.
The invention will be seen to provide an electronic adjustable pedal assembly for a motor vehicle in which the assembly may be readily adjusted to accommodate operators of varying anatomical dimensions, in which the ergometrics of the system remain constant irrespective of the position of adjustment of the pedal structure, and in which the desired hysteresis effect is provided in any position of adjustment of the pedal structure. Further, the invention pedal assembly provides the desired adjustability, the desired ergometrics, and the desired hysteresis effect in a structure that is simple, inexpensive, and positive and reliable in operation.
Whereas a preferred embodiment of the invention has been illustrated and described in detail, it will be apparent that various changes may be made in the disclosed embodiment without departing from the scope or spirit of the invention. For example, although the invention pedal assembly has been indicated for use in controlling the throttle of the associated vehicle, the invention pedal assembly may be used to electrically control a wide variety of vehicle functions or accessories. Further, although the resistance assembly 18 has been illustrated as providing the damping for an adjustable pedal assembly, it will be apparent that this resistance assembly can also be utilized to provide damping for a non-adjustable pedal assembly. | 4y
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BACKGROUND OF THE INVENTION
The invention concerns apparatus for binding loose sheets into binding covers provided at their backs with a thermoplastic adhesive, said apparatus comprising a frame and two parallel support walls that together form an input shaft to adjust the binding covers filled with the sheets, said shaft being defined at the bottom and during binding by a heating plate, and further comprising a deposition base to remove the finished, bound folder unit consisting of binding covers and sheets.
Such binding apparatus illustratively is described in the German patent 35 14 222. It comprises a frame with an input shaft formed by two parallel Vertical support walls. One support wall is stationary in the frame, the other is displaceably supported, namely being movable toward and away from the stationary one. In this manner the spacing between the two support walls can be mutually adjusted to maintain their parallel position.
The input shaft is defined underneath the adjustment zone of the displaceable support wall by a heating plate. This heating plate consists of an upper-side deposition base and an electric heater allowing to raise the deposition base to about 200° C. The heating plate is stationary.
In order to make a book or a notebook, first a stack of papers or also of plastic foils is formed which then is inserted into a binding cover. Such binding covers consist of a back with a joint to integrate the binding sides and further of a strip of hot-melt adhesive deposited on the inside of the back. When binding, the whole binding cover with the inserted sheet is introduced into the input shaft in such manner that the outside of the back comes to rest on the heating plate. Then the displaceable support wall is moved toward the stationary support wall in order that the whole binding cover retain its vertical position during binding. Next the heater plate is heated electrically to a temperature higher than the melting point of the hot-melt strip. This strip then softens and accordingly the sheets inserted into the whole binding cover sink by their lower edges into the strip of hot-melt adhesive and are wetted in the process. After a specified time the bound unit consisting of binding cover and sheets is removed from the binding apparatus and for that purpose the displaceable support wall is retracted. Thereupon the bound unit is either placed with the back facing down on a separate cooling stand or else, for instance in the case of the binding apparatus of the German patent 35 14 222 it is deposited--again with the back down--on a deposition base integrated into the binding apparatus where this bound unit can cool. The strip of hot melt solidifies again and hard binding of the sheets into the whole binding cover has thus been achieved.
The known binding apparatus suffer from the operational drawback that following binding, the bound units must be removed from the apparatus and be carried to a special deposition base. It is the object of the invention therefore to create a binding apparatus permitting easy cooling of the finished bound unit consisting of the binding cover and sheets.
This problem is solved by the invention for binding apparatus of the above species in that the heating plate and the deposition base are supported in movable manner in the frame in such a way that they can be alternatingly displaced into or out of the zone of the input shaft.
SUMMARY OF THE INVENTION
Accordingly the basic concept of the invention calls for the heating plate now to be displaceable and furthermore now to form a pair with the deposition base for the finished bound units, where this pair can be moved alternatingly into the zone of the input shaft. Therefore, following heating, the heating plate may be moved out of the input-shaft zone and instead the deposition base may be moved into it, whereby the bound unit is supported by the cool deposition base and thereby shall cool rapidly. Hence there is no longer the requirement to lift the bound unit out of the input shaft to achieve cooling. The bound unit can remain therein without as a result extending the cooling time. It will be removed only after cooling, at which time there is already a solid bond between the sheets and the binding cover, so that the bound unit is ready for use at once. That was not the case for the previously known solutions, wherein it might happen that during the movement from the input shaft to the deposition base, the sheets would shift inside the binding cover with attendant effects on the bond between binding cover and sheets.
In the implementation of the invention, the heating plate and the deposition base are guided in such manner that a binding cover present in the input shaft shall also be supported when switching from heating plate to deposition base.
It was found appropriate to guide the heating plate and the deposition base transversely to their longitudinal axes and to arrange them adjacent to one another, with heating plate and deposition base being supported in horizontally displaceable manner. Especially advantageously the heating plate and the deposition base shall be mounted together on a carriage, with the deposition base possibly being somewhat lower than the heater plate so that no impediments shall be encountered when switching from the heating plate to the deposition base.
Basically the switching motion of heating plate and deposition base can be carried out manually, for instance using a slider projecting from a frame or using a hand crank through a gearing mechanism. However, a binding apparatus anyway being powered electrically, at least one electric motor suggests itself to drive the heating plate and the deposition base into switching motions. In a simple embodiment mode, the electric motor(s) may be actuated by an electric switch accessible from the outside. Yet operation of the binding apparatus shall be even more convenient if a control regulating the energy to the heating plate and the electric motor(s) is provided to automatically turn on the electric motor(s) moving the heating plate out of, and the deposition plate into the zone of the input shaft after the power supply to the heating plate has been turned off or down. In many cases a control for the electric energy to the heating plate already is present (German patent 35 14 201). By a slight addition of switching means, this control can be so modified to also drive the motions of the heating plate and deposition base. In that case binding and cooling shall be fully automatic.
The control system may be perfected furthermore by being provided with a sensor detecting a binding cover in the input shaft, the control system actuating the electric motor(s) to drive the deposition base out of, and the heating plate into the zone of the input shaft when the sensor transmits an empty input shaft. By means of this control system the binding apparatus shall be returned--following cooling of the bound unit and its removal from the binding apparatus--into its initial state with the heating plate underneath the adjustment shaft, so that another binding procedure may start. Because this follows from the control system, again no operation is required. Alternatively, the control system may turn on the electric motor(s) to move the deposition base out of, and the heating plate into the input shaft when the power to the heating plate is turned ON or to full rated power.
Especially advantageously the design of the invention of heating plate and deposition base shall be supplemented with an electrically powered blower with an air duct to the lower region of the input shaft. Thereby the cooling of the bound unit shall be substantially accelerated and the input shaft can be cleared rapidly for new binding steps. In this respect radial cylinder blowers are recommended, which are very quiet and may be made to match the length of the heating plate with their axis of rotation parallel to the longitudinal axis of the heating plate. However axial blowers are equally applicable.
In another embodiment of the invention, at least one air flow baffle is provided which can be moved from a position in which the airflow is deflected from the input shaft to a position in which it is directed toward it. In this manner the heating plate shall not be exposed during heating, that is during binding, to the cooling air flow, in other words the air flow shall not degrade the effect of the heating plate. The air flow baffle(s) may be kinematically coupled to the heating plate and/or the deposition base that the air flow baffle(s) shall assume a position deflecting the air flow away from the input shaft when the heating plate is in the vicinity of the input shaft, and shall assume a position directing the air flow into the zone of the input shaft when the deposition base is in said zone. Accordingly the air flow baffle(s) so change(s) its (their) position(s) because of the motion of the heating plate or deposition base that the air flow only then will be made to pass into the zone of the input shaft when the deposition base shall be present in said zone. Where however a control system is provided to regulate the power to the heating plate it should include additional switching gear to control the blower in such a way that the blower will be turned on when the heating plate is turned off or turned down and/or when the heating plate is moved out of the input shaft, and so that the blower will be turned off when the heating plate is being moved out, or is out of the zone of the input shaft. Such circuitry is especially recommended because the blower power is called on only for cooling and because noise is restricted to that step.
Lastly, if so desired, the invention provides for a cover plate to cover the heating plate when in the position outside the input shaft zone to protect against the air flow to prevent cooling from it and so that the residual heat may be used for the next binding procedure.
BRIEF DESCRIPTION OF THE DRAWING
The invention is elucidated in the drawing by means of an illustrative embodiment. The drawing shows a vertical longitudinal section of a binding apparatus 1 for binding in particular paper sheets 2 into a binding cover 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The binding apparatus 1 comprises a frame 4 in the form of a boxy housing. It may consist of steel sheetmetal or plastic. In this view, it includes a left, flat segment 5 and a high segment 6 on the right. The high segment 6 includes a vertical support wall 7 limiting an input shaft 8. This input shaft 8 is limited on the other side by a further support wall 9 also forming a vertical surface and integrated into a slide component 10. The slide component 10 is seated in a horizontal guide slit 11 formed at the lower side by the ceiling 12 of the flat segment 5 of frame 4 and at the upper side by a guide wall 13 riveted onto the ceiling 12. A handle 14 stabilizes the slide component 10 and the support wall 9 and serves to slide in the directions of the double arrow A.
The input shaft 8 is limited at the bottom by a heater plate 15 acting through heater rods illustratively denoted by 16. The heater rods 16 are connected to an electric power supply. The heating plate 15 rests on a carriage 17 displaceably supported in horizontal manner in the directions of the double arrow B and thereby transversely to the longitudinal direction of the heating plate 15. The support has been omitted from the drawing for the sake of clarity. It may be a conventional roller support.
A deposition plate 18 is mounted on the left next to the heating plate 15 and also rests on the carriage 17. Its length (perpendicularly to the plane of the drawing) is about the same as that of the heating plate 15 and it is at about the same level. It can also be mounted somewhat lower.
The carriage 17 is provided at its base with an extension 19 itself comprising a borehole with a spindle nut. A spindle 20 passes through the spindle nut and rests on the left side in a bearing 21 and on the right side in a gear unit 22 to which is mounted an electric motor 23. The electric motor 23 is reversible, that is the spindle 20 can be rotated in both directions (double arrow C). Depending on the rotation of the spindle 20, the carriage 17 and thereby the heating plate 15 and the deposition plate 18 shall be moved horizontally in the directions of the double arrow B.
A cylinder blower 24 moving in the counter-clockwise direction, i.e. in that of the arrow D, is present in the upper part of the high segment 6. This blower is driven by an electric motor. The lower part of the high segment 6 of the frame 4 supports an air flow baffle 25 which pivots about the axis 26. Said baffle is in the position shown by solid lines during binding, namely resting against the back side of the stationary support wall 7. As a result the air flow is deflected from the input shaft 8 and made to pass through discharge louvers 27 out of the frame 4 (arrows E).
The above described binding apparatus operates as follows:
To prepare for binding, a stack of paper sheets 2 is inserted into the binding cover 3 between the binding sides 28, 29 in such a manner that the lower-end edges press against a hot-melt adhesive 30 deposited on, and affixed to the inside of the binding back of the binding cover 3. The strip of hot-melt adhesive 3 at this time is still hard because being at ambient temperature.
The unit consisting of the binding cover 3 and the paper sheets 2 is next inserted--as represented--into the input shaft 8, that is, standing and with the binding back 31 downward. For that purpose the displaceable support wall 9 is moved away from the stationary support wall 7 so that enough space be available for insertion. The binding back 31 thereby comes to rest by its outside against the heating plate 15. Next the movable support wall 9 is returned toward the stationary support wall 7 until the binding unit consisting of binding cover 3 and paper sheets 2 is clamped between the two support walls 7, 9.
Then electric power is applied to the heating plate 15. This may be carried out manually using a turn-on switch, but also automatically using a sensor, for instance a light barrier detecting the inserted bound unit. As a result the heating plate is raised to a temperature at which the hot-melt adhesive strip 30 softens and therefore the lower-end edges of the paper sheets 2 sink into the hot-melt adhesive strip 30 and are wetted by it. The duration of the power applied to the heating plate 15 may be controlled manually or by means of a regulator such as described in the German patent 35 14 201.
Following a time interval sufficient to soften the hot-melt adhesive strip 30, the electric motor 23 is turned on in such a direction that the carriage 17 and hence the heating plate 15 and the deposition plate 18 are moved to the right in this Figure. The electric motor 23 may be turned on manually, for instance when the binding apparatus 1 transmits a suitable signal upon termination of heating, or it may take place automatically by the time-control lowering the power to the heating plate 15 at the end of the heating phase or even turning it off. In this manner the heating plate 15 arrives in the zone of the high segment 6 of the frame 4 until it assumes the position shown in dash-dot lines. In this process it, i.e. the carriage 17 impacts and forces the air baffle 25 into the same direction, whereby it shall come to rest against the back wall 32 of the high segment 6. The air flow issuing from the cylinder blower 24 therefore cannot find its wa to the discharge louver 27, in other words the air flow is now constrained to move toward the flat segment 5 of the frame 4.
Because of the displacement of the carriage 17, the deposition plate 18 arrives in the zone of the input shaft 8 of which it then forms the lower boundary. Thereby the binding back 31 slips from the heating plate 15 onto the deposition plate 18. Appropriate insulating steps assure that the deposition plate 18 shall not be heated by the energizing of the heating plate 15, i.e., it will form thereupon a cool surface for the heated binding back 31. For that purpose the deposition plate 18 also may be designed as a perforated plate or the like. Contact with the deposition plate 18 entails rapid cooling of the binding back 31 and hence to solidification of the hot-melt strip 30. This is enhanced by the cool air flow generated by the cylinder blower 24 and deflected by the air baffle 25 toward the input shaft 8.
Upon solidification of the hot-melt strip 30, the paper sheets 2 have been firmly affixed to the binding cover 3. At the end of the cooling, the bound unit of binding cover 3 and paper sheets 2 is ready for immediate handling without thereby affecting the bond between the binding cover 3 and the hot-melt adhesive strip 30.
The carriage 17 may be manually reset into the position shown in solid lines by actuating a suitable switch, but also by means of a corresponding control system. In the former case the termination of cooling may be displayed by a suitable signal which will be ON after a specific time. In the latter case, a number of controls are possible. Illustratively the return of the carriage 17 may be controlled by a sensor which upon the removal of the bound unit detects the empty input shaft 8 and thereby turns on the electric motor 23 in a direction of rotation that displaces the carriage 17 to the left until it assumes again the initial position with the heating plate 15 in the zone of the input shaft 8. However the control also may be such that said motion shall be initiated only after a new binding cover 3 has been inserted and the heating plate 15 has been energized.
Jointly with the return of the carriage 17, the baffle 25 moves back into the position wherein it rests against the back side of the stationary support wall 7. This motion illustratively can be implemented by a spring but also by kinematics to the carriage 17. In addition or alternatively to the movable air baffle 25, the cylinder blower 24 also may be included into the automatic control in such a way that it shall be only actuated and shall only be operational as soon and as long as the carriage 17 moves to the right and the deposition plate 18 is underneath the input shaft 8. Where appropriate, the heating plate 15 may be moved underneath a covering protecting it from the air flow of the cylinder blower 24. | 4y
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BACKGROUND OF THE INVENTION
Safety precautions in the woodworking shop require shields which surround whirling saw blades and project forwardly from the cutting edge thereof, the shield being arranged for pivotal movement on a horizontal axis so that as the piece to be cut is introduced to the shield, the shield is tilted upwardly to provide clearance for the piece introduction. As the piece passes beneath the shield and through the saw blade, the shield is brought back downwardly in a horizontal position over the piece being cut for protecting the operator from the saw.
There is no suggestion of any arrangement for stopping operation of the saw motor when the guard is tilted for introduction of the piece to be cut.
Inasmuch as there is nothing in the prior art on controlling the operation of the saw motor establishing the operating parameters that the guard must always be in operating position as actuated by the thickness of material being cut for the saw motor to run, and/or in the event that the operator should move away from the table without pushing the motor-stop button whereby a time-delay switch will automatically shut off the motor after the passage of the set period of time, there is thus an established need for a combination of electrical controls with an actuating mechanism for the guard which will perform these operations.
SUMMARY OF THE INVENTION
The gist of this table-saw guard lies in a motor-starter circuit having automatic switchgear in combination with the saw motor and mechanism for operating the guard which will shut off the saw-motor drive if said guard is not in the correct operating position covering the whirling blade. A limit switch senses the position of the guard above the thickness of the material being cut, and a mercury switch senses if the guard is not perfectly horizontal thereabove. A time-delay circuit in series with the limit and mercury switch circuits shuts off the saw motor should the operator move away from the table without first pushing the stop-button in the saw motor starter box and 42 seconds shall have passed. A lock and key switch manually over-rides the automatic shut-off switchgear for hard-to-do-jobs.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective cut-away fragmentary view of the table-saw guard of this invention;
FIG. 2 shows a front view of the same;
FIG. 3 shows an enlarged fragmentary side view of the mechanically-operated limit microswitch mounted near the cutting teeth of the saw in the path of the workpiece and actuated by its passage;
FIG. 4 shows the bypass switchbox for hard-to-do jobs, the key to which is held by the supervisor; and
FIG. 5 shows a schematic diagram for the guard and work positioning and time delay power shut-off circuits.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a table 8 supports an overhead arm 10 having a rear portion which is mounted on a thin steel strut plate 12 which in turn is supported on the table 8 in alignment with and having a thickness no greater than a saw blade 14. A guard 16 comprising an arcuate yoke 18 having front and rear arms which surround the portion of the blade at the saw 14 projecting above the top surface of table 8 projects downwardly from the front portion of the arm 10 in the direction of contacting its lower surface with the top surface of the workpiece (not shown) below having a guard vertical-positioning means 19 movably adapted for motion up and down of the guard 16 in the vertical direction relative thereto. Right-hand and left-hand clear plastic covers 20a and 20b, as shown in FIG. 2, cover each side of the arcuate yoke 18 disclosing that portion of the blade of the saw 14 above the top surface of table 8 centrally located therebetween and both sides of the piece work being fed to the saw below for full view by the operator while the cut is being made with the full protective benefit of the guard 16 in place. A yoke shank 22 which is structurally a portion of the arcuate yoke 18 extends upwardly from the central portion thereof into the front portion of beam 10. Pads 24 and 26 extend forwardly and rearwardly from the front and rear arms of the arcuate yoke 18, respectively, having lower surfaces contacting the top surface of the workpiece below. First tongue and groove joint 28 slidingly mates the aft end of pad 28 with the front vertical edge of thin strut plate 12 for guiding the arms of the yoke 18 in their vertical up and down movement relative to the workpiece below. Guard tilt-hinging means 30 which is structurally mounted on table 8 below the top surface thereof engages the strut plate 12 for lateral support which is adjustable in the fore and aft and hinged in the up and down directions in order to properly locate the guard 16 with respect to the saw 14 and the workpiece being operated upon below.
Reference to FIG. 3 shows a guard vertical position-sensing saw-motor shut-off switching means 31 comprising a limit switch 32 which mounts on pad 24 off the forward arm of yoke 16 having an actuating roller plunger 34 which extends in a downwardly direction therefrom for contacting the top surface of the workpiece below and making electrical contact therein whenever a workpiece of predetermined thickness is in postion for cutting. The electrical contact in the switch 32 is opened immediately when the workpiece is removed.
Second tongue and groove joints 36a and 36b each slidingly mate each of the fore end and midportion of arm 10 with each of the fore and back sides of the yoke shank 22, respectively, as shown in FIG. 1, for guiding the shank 22 of the yoke 18 in its vertical up and down movement relative to the workpiece below. Rack and pinion drive 38 mounts on the right side of the yoke shank 22 having one end of a pinion drive shaft 40 extending rearward therefrom wholly within the overhead arm 10 for moving the guard 16 in its vertical up and down movement relative to the workpiece below. A step-down gear box 42, having a reversing motor drive 44 operationally connected thereto, mounts on the rear end of arm 10 and operationally couples its output shaft to the other end of the pinion drive shaft 40, for driving the rack and pinion drive 38 and moving the guard 16 in its vertical up and down movement.
As shown in FIGS. 4 and 5, a control box 46 mounts on beam 10, having a source of 110 volts A.C. power including D.C. power supply circuit 70 which shunts across the secondary of a transformer 50 having its primary connected to an A.C. power source through the fuse 56. Circuit 70 comprises a full-wave bridge rectifier 72 operationally connecting to the power source, and a saw-motor starter circuit 74 having a second relay-actuating coil 76 operationally connecting one terminal thereof to the hot output of rectifier bridge 72. A voltage limiting diode 78 shunts out the relay coil 76.
A saw-motor starting circuit switching means 79 comprising a triac 80 operationally connects its main terminal 2 to the other terminal of the coil 76 and its main terminal 1 to ground for switching the saw-motor starter circuit 74 on and off. A triac trigger circuit 82, which series-connects its input through a first relay-actuated switch 83 having first, and fourth relay-actuating coils 112 and 116, respectively (not shown), a first resistor 84 and a diode 86 to the hot output of rectifier bridge 72, comprises a PNP transistor 88 having its collector terminal connected through a second resistor 90 to the gate terminal of said triac 80 and through a parallel third resistor 92 to ground. The emitter terminal of said transistor 88 connects to the output terminal of first switch 82 through a third resistor 94.
A time-delay saw-motor shut-off circuit 96 comprises series-connected resistances 98 and 100 which connects its input terminal to the output terminal from first switch 82. The base terminal of transistor 88 connects to the output terminal of series-connected fourth and fifth resistances 98 and 100. A first capacitor 102 connects its high-voltage terminal to the output terminal of series-connected resistances 98 and 100 and its low-voltage terminal to ground. A sixth resistance 104 connects its input terminal to the base terminal transistor 88 and its output terminal through diode 106 in series-connection with two-point make limit microswitch 108.
A guard horizontal position-sensing saw-motor shut-off switching means 110, which connects to the output of first resistor 84, comprises a first relay coil 112 having its input terminal connecting to the output thereof. A mercury switch 114, which horizontally mounts on the guard arm 10 and is oriented in the fore-and-aft direction thereon, connects its input terminal to the output terminal of coil 112. A second relay-actuated switch 116 having first and third relay-actuating coils 112 and 54, respectively, connects its input terminal to the output terminal of the mercury switch 114 and its output terminal to the input terminal of a third relay-actuated switch 118 having first and second relay-actuating coils 112 and 76, respectively, the output of which connects to ground.
In the control box 46, having the source of 110 volt A.C. power, an A.C. power supply circuit 48 operationally connected thereto comprises the step-down transformer 50, a guard-motor starter box 52 operationally connected thereto having a third relay-actuating coil 54 connected at one terminal thereof through the fuse 56 to one terminal of the secondary of the step-down transformer 50. A runlight (green) 58 shunts across the relay coil 54. A bypass keyswitch 60 which is in series connection with the relay coil 54 operationally connects the same across the secondary of transformer 50 through fuse 56 when closed. A third relay-actuated switch 62 having first and second relay-actuating coils shunts across the keyswitch 60. A fourth reversing polarity means 64 having first and second up/on pushbutton switches 66 operationally actuating relay-actuating coil 54 operationally connects with the reversing A.C. motor 44 for moving the guard 16 in its vertical up and down movement relative to the workpiece below according to the setting of toggle switch 66 on the front panel of control box 46. A set material thickness light (red) 68 shunts across the motor 44.
An operator has 42 seconds to start a cut after setting the guard 16 at its working height, by means of the switch means 66, where the roller plunger 34 contacts the workpiece to close the switch 32. As long as the operator is operating or cutting, the saw 14 will continue to run. If the operator leaves the site of operation without turning the saw 14 off, the switch 32 will be open and the saw 14 will be shut off automatically after the preset waiting period, for example, the before mentioned 42 seconds.
There is a bypass keyswitch 60 for hard-to-do-jobs. However, the key of switch 60 is held by the supervisor who must then supervise the setting of the saw 14 and make sure that it is put back into the automatic safety position.
It will be understood that details of the construction shown may be altered or omitted without departing from the spirit of the invention as defined by the following claims. | 4y
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BACKGROUND OF THE INVENTION
The present invention relates to ornaments and decorations formed from pleated material; and more particularly to methods and apparatus for manufacturing such ornaments and decorations.
Decorative objects for adorning the outside of gift wrapped packages have been created from sheet material that has been repeatedly folded in a pleated pattern. For example, a butterfly 10 shown in FIG. 1 is formed by upper and lower pleated segments 11 and 12. The two pleated segments then are held in a compacted manner against each another along seam 14. A tie 16 is placed around the middle to hold the bundled segments 11 and 12 together. Next the outer edges 18 and 19 of segments 11 and 12, respectively, were fanned out to form the butterfly shape, while the midpoint is held compressed by the tie 16. The center tied area is covered by a piece of felt 17 cut in the shape a butterfly thorax. An adhesive patch (not shown) can be attached to the underside of the decorative object for fastening to a gift package, or other surface.
Previously, the sheet material which formed segments 11 and 12 of the butterfly 10 was folded into pleats by hand and then manually compressed and held together while tie 16 was applied. The hand folding operation was tedious and did not always produce uniformly pleated material which was obvious in the finished object. With complex decorations, a single assembly person found it difficult to compact several segments 11 and 12 and hold them together while applying the tie. Unless the two segments 11 and 12 were firmly compacted during the tying process, the segments were not always securely fastened together, which also adversely affected the appearance of the finished ornament.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method and apparatus which allows one person to manufacture a pleated ornament, and especially a multiple segment ornament.
Another object of the present invention is to provide an apparatus that enables one assembly person to rapidly fabricate the pleated ornament.
A further object of the present invention is to provide a method and apparatus for manufacturing a plurality of decorative ornaments with a high degree of uniformity.
Yet another object of the present invention is to provide a method and manufacturing apparatus which can be utilized to produce a wide variety of different pleated ornaments.
An ornament is made by a method in which the first step is producing a blank of the ornament from a sheet of material. That flat blank then is fed between a pair of rotating rollers having intermeshed teeth which produce a series of pleats in the blank.
The pleated blank is placed between a pair of parallel plates which are spaced apart by a distance approximately equal to the width of the pleats. Then a compressor plate is slid between the pair of parallel plates to gather together the pleats of the blank. For example, the compressor plate compacts the pleated blank against a stop that is located between the parallel plates near one edge.
The parallel plates have openings that enable a tie to be placed around the compacted blank and then secured to hold the pleats in a gathered state. An operator removes the tied blank from between the plates and fans out the pleats on at least on side of the tie to form the shape of the finished ornament.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 Is a plane view of an exemplary pleated ornament in the form of a butterfly;
FIG. 2 is an isometric view of a machine for creasing a blank of the ornament;
FIG. 3 is a cross sectional view taken along line 2--2 of FIG. 2;
FIG. 4 is an isometric view of a pleat compressor used in the manufacture of the ornament;
FIG. 5 is a top view of the pleat compressor in one stage of operation;
FIG. 6 is a top view of the pleat compressor in a subsequent stage of operation; and
FIG. 7 is a flowchart of the manufacturing process used to produce a pleated ornament.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in the context of producing a decorative butterfly 10 shown in FIG. 1. However, it will be understood by those skilled in the art that numerous other types of pleated decorative objects can be fabricated using the present method and apparatus.
With reference to FIGS. 2 and 3, a creasing machine 20 is utilized to produce periodic creases in a sheet of material, such as decorative paper or foil paper used in gift wrapping, and create a pleated pattern. The creasing machine comprises an rectangular frame 22 with a pair of vertical walls 23 and 24 spaced apart by bottom and top walls 25 and 26, respectively, and with open left and right sides as oriented in the drawings. A pair of rollers 28 and 29 extend between vertical walls 23 and 24 within frame 22 and have shafts at each end that are mounted to bearings 30 on the vertical walls enabling the rollers to rotate about their longitudinal axes. A shaft at one end of the lower roller 28 extends through an aperture in wall 24 and is connected to a transmission 32. An electric motor 34 drives the transmission 34 thereby producing rotation of rollers 28 and 29 in directions indicated by a curved arrow associated with each roller in FIG. 3.
The rollers 28 and 29 have gear teeth 31 cut longitudinally along their curved surfaces. As the rollers rotate within frame 22, the teeth of lower roller 28 mesh with the teeth of upper roller 29. The spacing between the rollers 28 and 29 allows a sheet 66 of material to pass in-between the rotating rollers to create pleats in the sheet.
A guide tray 36 is mounted at an angle between the two vertical walls 23 and 24 of the frame 22 with an inner edge of the guide tray aligned with the region at which the two rollers 28 and 29 mesh. A shield 38 extends within the frame 22 substantially perpendicular to the guide tray 36 with a small gap there between which allows a sheet 66 of material to pass into the rollers 28 and 29. The shield 38 prevents the operator's fingers from accidentally contacting the upper roller 29 while feeding the sheet 66 into the creasing machine 20.
With reference to FIGS. 4 and 5, a pleat compressor 40 is utilized to gather together the pleats of a creased sheet of material into a compacted form. The pleat compressor 40 has a flat metal base plate 42 with a horizontal V-shaped groove 44 cut in one longitudinal edge 46 and a narrow rectangular notch 47 extends farther into the base plate from the apex of the groove. A pair of aligned stop members 48 and 50 are attached to the top surface 61 adjacent the longitudinal edge 46 of the base plate 42. Each of the stop members 48 and 50 has a tapered end 51 and 52, respectively, which conforms to the angle of the V-shaped groove 44 and is aligned with a edge of that groove. The two stop members are spaced apart from one another to form a gap 54 at the apex of the V-shape groove 44 in the base plate 42 which gap 54 exposes the notch 47 in the base plate.
A transparent plastic cover plate 56 is coupled by a hinge 58 to the top surface 61 of base plate 42. Specifically the hinge is connected to the cover plate along short side 41 that is adjacent and parallel to one short side 45 of the base plate. The hinge 58 spaces the cover plate 56 above the top surface 61 of the base plate by the thickness of the two stop members 48 and 50. The stop member thickness also defines spacing between the two plates when the cover plate 56 is in a closed position parallel to the base plate 42. The spacing between plates 42 and 56 corresponds to the width of each crease of the sheet material produced by the creasing machine 20. The cover plate 56 extends over the two stop members 48 and 50 and rests against those plates in the closed position. A rectangular notch 60 is cut in an edge of the cover plate 56 and aligned with the apex of the V-shaped groove 44 in the base plate 42 when plates 42 and 56 are closed parallel to each other as shown in FIG. 5.
The pleat compressor 40 also includes a compressor plate 62 which is slightly larger than the cover plate 56 and has a thickness equal to the spacing between the cover plate 56 and the base plate 42 when pleat compressor is closed. Thus when the pleat compressor 40 is closed, the compressor plate 62 is able to slide between the cover plate 56 and the base plate 42 as illustrated in FIGS. 5 and 6.
FIG. 7 illustrates a flowchart of a process which uses the sheet creasing machine 20 and the pleat compressor 40 to manufacture a ornament, such as butterfly 10 in FIG. 1. Initially at step 70, a blank 66 for the ornament is cut from sheet material, such as heavy gift wrapping paper or foil, for example. In the case of the butterfly 10, separate blanks are cut out for each of the segments 11 or 12. The flat blank 66 then at step 72 is fed through the creasing machine 20 as shown in FIG. 3. In doing so, an operator places the blank 66 on the guide tray 36 and pushes the blank into the machine to engage the rotating rollers 28 and 29. The flat blank 66 is drawn between the rollers which creases the material forming a series of pleats 68 as the sheet exits the rollers as a creased blank 69.
Next at step 74, the operator places the creased blank 69 onto the top surface 61 of pleat compressor 40 with the pleats running parallel to the stop members 48 and 50, as shown in FIG. 5. The creased blank 69 is oriented with respect to the gap 54 between the two stop members 48 and 50 so that the point in the blank at which the tie will be attached is aligned with that gap. For the butterfly 10, the pleated blank 69 is centered at the gap 54. The cover 56 of the pleat compressor 40 is closed over the pleated blank 69 until it contacts the stop members 48 and 50, thus reaching the closed position.
The operator then at step 76 slides the compressor plate 62 in-between the base plate 42 and cover plate 56 toward the stop members 48 and 50 in the direction indicated by arrow 63. When the inner edge 64 of the compressor plate 62 contacts the pleated blank 69, further movement of the compressor plate causes a gathering of the pleats and a compression of the blank against the stop members 48 and 50. The compressor plate 62 is pushed into the compressor 40 until the pleated blank 69 is fully compacted against the stop members 48 and 50. In the case where the decorative object is formed by two pleated segments, such as the butterfly 10, both segments may be compressed separately and then placed together in the pleat compressor 40 for tying together.
The tie 16, such as colored wire or a pipe cleaner, is passed through notch 60 in the cover plate 56 and notch 47 in the base plate 42 on one side of the compacted blank 69, at step 78. The ends of the tie then are bent around the compressed blank 69 into the V-shaped groove 44 and twisted to tightly hold the middle portion of the blank together. In the case of the butterfly 10, the ends of the tie 16 form the antenna of the finished ornament. In other types of decorative objects made in this manner, the exposed ends of the tie 16 can be cut off upon removal of the ornament from the compressor 40.
The blank 69 is removed from the pleat compressor 40 at step 80 and the operator manually fans out the portions of the blank on each side of the tie 16 at step 82. In the case of the butterfly 10, the fanning out of these portions of the blank form wings. Once the pleats have been fanned out, additional finishing steps may be performed at step 84. For example, these steps include applying a felt cut-out 17 which forms the thorax of the butterfly 10 and attaching an adhesive pad so that the decoration can be fastened to a package or other surface. For other decorations a ribbon can be placed around the tie. | 4y
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TECHNICAL FIELD
The present invention relates to the technical field of furniture hardware. More specifically, the present invention relates to latch mechanisms which are capable of both aligning and selectively locking together two furniture parts such as table halves and auxiliary table leaves.
BACKGROUND OF THE INVENTION
A long standing problem in extension tables and other similar furniture has been the proper alignment of the table halves and/or leaves with respect to one another. That is, to cause the table halves and/or leaves to come together with the table top and table edges aligned, thereby providing an overall flat top surface and preventing people from catching themselves on misaligned edges. Misaligned table tops and side edges are also quite unsightly and undesirable.
Another long standing problem in extension tables and leaves is that they tend to creep apart over time, creating an unsightly gap in between the table halves and/or leaves. Such unsightly gap can also be unsanitary, since food particles tend to become lodged therein. Furthermore, with the table halves improperly secured to one another, the table is typically less stable.
Although numerous latch mechanisms have been devised in the past for aligning and locking together table halves and leaves, such prior latch mechanism have shortcomings and drawbacks. The prior latch mechanisms have failed to provide positive alignment both vertically and horizontally (side to side) while providing a positive locking function for detachably attaching the table halves and/or leaves together and preventing them from creeping apart. Accordingly, a need exists for a latch mechanism that is generally inexpensive to manufacture and which provides positive horizontal and vertical alignment of the furniture parts and, further, which selectively provides positive locking between the furniture parts and prevents them from creeping apart from one another.
SUMMARY OF THE INVENTION
It is the principal object of the present invention to overcome the above discussed disadvantages associated with prior latch mechanisms.
The present invention overcomes the disadvantages associated with prior latch mechanisms by providing a strike member which is adapted to be mounted to a first furniture part or table half. The strike member includes a pair of fingers extending beyond the table half edge and generally perpendicular thereto. A lock member is also provided and is mounted to a second furniture part or the other table half. The lock member includes a base which, when mounted to the second furniture part, forms a pair of apertures between the base and the second furniture part. The lock member is located and mounted on the second furniture part in a manner whereby, when the edges of the first and second furniture parts are brought together, the strike member finger are received within the respective pairs of lock member apertures.
The latch mechanism further includes an arm pivotally attached to the lock member and which is adapted to selectively be pivoted for engaging an ear located on the strike member. More specifically, initial rotation of a handle, places the arm in a position generally extending parallel to the strike member fingers, and placing a boss at the end of the arm adjacent an ear on the strike member. Additional rotation of the handle causes engagement of a cam member causing the arm to move parallel to the strike fingers toward the lock member thereby causing the arm boss to engage the strike ear and pull the strike member toward the lock member and, also, pulling the strike member fingers into the respective lock member apertures. Accordingly, the first and second furniture parts or table halves are tightly pulled together without any gap therebetween and, because the strike member fingers are received within the lock member apertures, the furniture parts are retained positively aligned with one another both horizontally and vertically.
It is noted that, depending on the edge length of the furniture parts or table halves and leaves, a plurality of latch mechanisms may be used as needed to align and lock the two furniture parts together. Additionally, because the latch mechanism is typically used on wood furniture parts, both the strike member and lock member are each provided with a pair of holes adapted to receive a screw for mounting the strike members and lock members to their respective furniture parts.
Preferably, the strike member fingers are connected to one another at a head portion and the head portion and fingers generally form a U-shape. The strike member is also preferably made of metal by a stamping process and the fingers are generally coplanar with one another. The ear is integrally formed by bending a tab at the head portion to an angle with respect to the coplanar fingers. Additionally, the arm is pivotally attached to the lock member in between the lock member apertures thereby evenly pulling on the strike member and generally evenly distributing the pulling force through the strike member ear to each of the strike member fingers.
In one form thereof, the present invention is directed to a selectively lockable and horizontally and vertically aligning latch mechanism for selectively aligning and fastening two furniture parts. The latch mechanism includes a strike member having a pair of fingers. The strike member is adapted to be mounted to a first furniture part. A lock member is also provided and includes a base adapted to be mounted to a second furniture part. A pair of apertures are formed between the base and the second furniture part. The strike member pair of fingers are selectively received in the respective pair of apertures when the first and second furniture parts are brought together. A latch member is provided for selectively detachably attaching the strike member and first furniture part to the lock member and second furniture part when the pair of fingers are received within the respective apertures.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and objects of this invention and the manner of obtaining them will become more apparent and the invention itself will be better understood, by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a cross-sectional partial view of two table halves and showing a latch mechanism constructed in accordance with the principles of the present invention mounted on and retaining the tables halves together;
FIG. 2 is a perspective view of the latch mechanism shown in FIG. 1 with the strike member and lock member separated from one another;
FIG. 3 is a perspective view of the latch mechanism shown in FIG. 1, and wherein the strike member fingers are received within the lock member apertures;
FIG. 4 is a perspective view of the latch mechanism shown in FIG. 1, and wherein the lock member arm is pivoted approximately 90 degrees and generally parallel to the strike member fingers;
FIG. 5 is a perspective view of the latch mechanism shown in FIG. 1, and wherein the lock member handle is pivoted to its fully latched position and the lock member arm is moved parallel with the strike member fingers and causing the arm boss to engage the strike member ear and pull the strike member fingers toward the lock member apertures;
FIG. 6 is a top plan exploded assembly view of the lock member shown in FIG. 2;
FIG. 7 is a sectional view taken generally along line 7--7 of FIG. 6;
FIG. 8 is a front elevation view of a lock member base mounted on a furniture part and forming a pair of apertures in accordance with the principles of the present invention;
FIG. 9 is a top plan view of an alternate embodiment of strike member constructed in accordance with the principles of the present invention;
FIG. 10 is a front elevation view of the strike member shown in FIG. 2;
FIG. 11 is a top plan view of the latch mechanism shown in FIG. 1, with the handle removed, and wherein the strike member and lock member are separated from one another;
FIG. 12 is a top plan view of the latch mechanism shown in FIG. 11, and wherein the strike member fingers are received within the lock member apertures;
FIG. 13 is a top plan view of the latch mechanism shown in FIG. 11, and wherein the lock member arm is rotated generally parallel to the strike member finger; and,
FIG. 14 is a top plan view of the latch mechanism shown in FIG. 12, and wherein the lock member arm has been moved longitudinally toward the lock member causing the arm boss to engage the strike member ear and pulling the strike member fingers into the lock member apertures.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
The exemplifications set out herein, illustrate preferred embodiments of the invention in one from thereof and such exemplifications are not to be construed as limiting the scope of the disclosure or the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIG. 1, an extension table is shown and generally depicted by the numeral 10. Extension table 10 includes a first table top 14 and a second table top 16 and respective table aprons 18 and 20. Table tops 14 and 16 are selectively extendable apart from one another in a known and customary manner, for example, for adding leaves therebetween and increasing the overall table size. Table top 14 includes a top surface 22, bottom surface 24 and a horizontal inner side edge 26. Table top 16 includes a top surface 28, bottom surface 30 and horizontal inner side edge 32.
A latch mechanism constructed in accordance with the principles of the present invention is shown in the drawings and generally designated by the numeral 34. Latch mechanism 34 includes a strike member 36 adapted to be mounted as shown in FIG. 1 to bottom surface 24 of first table top 14 and adjacent the horizontal inner side edge 26. Latch mechanism 34 also includes a lock member 38 adapted to be mounted on the bottom surface 30 of second table top 16 and adjacent its horizontal inner side edge 32. As shown and as more fully described hereinbelow, latch mechanism 34 functions to selectively align table tops 14 and 16 both horizontally and vertically and, further, to selectively retain the table tops locked together and preventing them from creeping apart during normal use of the table.
Strike member 36 is preferably made of metal with a thickness of 0.040 to 0.20 inch. Strike member 36 is made by a stamping process and includes a pair of fingers 40 having forward ends 42. At their other end, fingers 40 are integrally connected to one another via head portion 44. As shown, head portion 44 and fingers 40 generally form a U-shape with a central channel 46. Fingers 40 and head portion 44 are generally coplanar with one another. An ear 48 is located in between fingers 40 at the bottom of channel 46, and extends generally perpendicularly upwardly therefrom. Ear 48 is formed by cutting its side edges 50 from fingers 40 and bending upwardly at bend line 52 to a position as shown. More preferably, ear 48 is bent slightly past the vertical and to an acute angle with respect to head portion 44.
Strike member 36 is further formed having an outer perimeter band 54 and inner perimeter band 56 stamped on to the strike member and creating a central raised portion 58 therebetween. Outer and inner perimeter bands 54 and 56, together with central raised portion 58, create a shallow channel beam structure thereby strengthening fingers 40, head portion 44 and the inter connections therebetween. Strike member 36 is further provided with a pair of holes 60 with chamfered walls 62 adapted to receive a wood screw (not shown) for mounting the strike member 36 on to the bottom surface 24 of first table top 14 as shown in FIG. 1.
The latch mechanism lock member 38 is made of the plurality of components each also made of metal with a thickness of 0.040 to 0.20 inch by stamping and forming processes. Lock member 38 includes a base 64 as best shown in FIGS. 6-8. Base 64 is formed having a top platform 66 which is integrally connected to and located at a slightly higher level than intermediate platform 68. Top platform 66 and intermediate platform 68 are integrally connected with one another via walls 70. Intermediate platforms 68 are located above and are each integrally connected to respective feet 72 via walls 74. At the rear of base 64, rear wall 76 extends and is integrally connected to feet 72, walls 74, intermediate platforms 68, walls 70 and top platform 66. Each of feet 72 are provided with a hole 78 defined by chamfered walls 80 and adapted to receive a wood screw (not shown) for mounting lock member 38 to the bottom surface 30 of second table top 16.
At the front of base 64, a tongue 82 is provided and is integrally interconnected with top platform 66 via front wall 84. Tongue 82, as shown, is generally coplanar with feet 72. As best shown in FIGS. 11-14, tongue 82 and front wall 84 are slightly smaller in width than the width of central channel 46 of strike member 36. Accordingly, a pair of apertures 86 are formed generally between walls 74, intermediate platform 68, front wall 84 and portions of bottom surface 30 of table top 16. As shown, the openings to apertures 86 are adjacent front wall 84. Further, apertures 86 extend backwardly toward and terminate at base rear wall 76.
In operation, fingers 40 are selectively received within apertures 86 and tongue 82 is received within central channel 46 whenever first and second table tops 14 and 16 are brought together. Because strike member 36 is securely mounted to table top 14 and base 64 of lock member 38 is securely mounted to table top 16, the table tops are caused to be aligned both horizontally and vertically. Furthermore, fingers 40 and apertures 86 are sized so as to have a generally close fit, thereby preventing excess play and positively providing accurate horizontal and vertical alignment.
Referring now more specifically to FIGS. 6, 7 and 11-14, the top platform 66 includes a top flat surface 88. Top platform 66 is also provided with a pivot hole 90 and a radial opening 92 communicating with a rectangular opening 94.
An arm 96 is provided overlaying top platform 66. Arm 96 is also made of metal via a stamp forming process. A boss 98 is provided at one longitudinal end of arm 96 and is formed by bending downwardly the end portion of arm 96. Boss 98, as shown, is bent to a position generally perpendicular to arm 96 and, more preferably, is bent to form an acute angle with respect to arm 96. At its other longitudinal end, arm 96 includes a tab follower 100. Tab follower 100 is formed quite similar to boss 98 by bending a portion of arm 96 downwardly and generally perpendicular to arm 96. Arm 96 further included an L-shaped opening 102 located intermediate tab follower 100 and boss 98. When arm 96 is received over top platform 66, L-shaped opening 102 of arm 96 communicates with pivot hole 90 of base 64. Further, tab follower 100 of arm 96 extends into radial and rectangular openings 92 and 94 of base 64.
Lock member 38 also includes a handle 104 having a grip blade 106, a central pivot hole 108 and a cam pin 110. Grip blade 106 is preferably formed as shown by bending wing portions 112 downwardly and forming an area whereat an operator may readily grasp and turn the handle. Cam pin 110 is preferably formed by punching the metal thereat perpendicularly and thereby forming the cam pin 110 extending downwardly from the bottom face 114 of handle 104. Handle 104 is received over arm 96 with its central pivot hole 108 communicating with L-shaped opening 102 of arm 96 and pivot hole 90 of base 64. Additionally, cam pin 110 of handle 104 is received within the L-shaped opening 102 of arm 96.
Base 64, arm 96 and handle 104 are assembled and retained together, as shown, via a rivet 116 extending through central pivot hole 108 of handle 104, L-shaped opening 102 of arm 96, and pivot hole 90 of base 64. Rivet 116 is placed and secured therein in a known customary manner and so as to allow relative pivotal motion between handle 104, arm 96 and base 64.
In operation, as best shown in FIGS. 2-5 and 11-14, prior to locking the strike member 36 and lock member 38 to one another, the table top halves 14 and 16 are brought together placing fingers 40 within apertures 86 and tongue 82 within central channel 46. In this position, as shown in FIG. 3, arm 96 and handle 104 extend generally parallel to one another and perpendicular to fingers 40. As can be appreciated, in this position, neither arm 96 nor handle 104 obstruct the apertures 86, thereby allowing fingers 40 to readily and easily be received therein. It is noted that in this position, as shown in FIGS. 11 and 12, the tab follower 100 extends into and is located within radial opening 92 and rivet 116 is located at the central area of L-shape opening 102.
By rotating the handle 104 approximately 90 degrees from the position shown in FIG. 3 to the position shown in FIG. 4, cam pin 110 is also rotated about 90 degrees about rivet 116 as indicated by arrow "A". Simultaneously, tab follower 100 slides radially along radial opening 92 to within rectangular opening 94 as shown in FIG. 13. This also pivots the entire arm 96 approximately 90 degrees to a position as shown in FIGS. 4 and 13 whereat arm 96 extends over ear 48 and boss 98 is adjacent thereto and over head portion 44 of strike member 36.
By turning handle 104 an additional approximate 90 degrees from the position of FIG. 4 to the position shown in FIG. 5, arm 96 is moved in a direction generally parallel to fingers 40 and toward lock member 38 thereby causing boss 98 of arm 96 to engage the ear 48 of strike member 36 and thereby also urging or pulling the strike member and first table top 14 toward the lock member 38 and second table top 16. More specifically, as shown in FIGS. 13 and 14, as handle 104 is pivoted further toward the position shown in FIG. 5, cam pin 110 is urged backwardly as indicated by arrow "B" thereby causing tab follower 100 to move within rectangular opening 94 backwardly toward rear wall 76 and thereby also placing rivet 116 within one leg of the L-shaped opening 102. As can be appreciated, in this manner, boss 98 engages ear 48 thereby locking the strike member 36 and lock member 38 together as shown.
For unlocking the strike member 36 from the lock member 38, handle 104 is merely rotated in the opposite direction first causing arm 96 to move in a direction parallel to fingers 40 and placing the arm 96, rivet 116, cam pin 110, tab follower 100 etc., in the positions as shown in FIG. 13. Additional turning of handle 104 to a position as shown in FIG. 3 causes arm 96 to be rotated to a position as shown in FIGS. 12 and 3 thereby unlocking the strike member 36 and lock member 38 and thereby allowing them to be pulled apart and removing fingers 40 from apertures 86.
In FIG. 9 there is shown an alternate most preferred embodiment of the strike member 36 wherein outer and inner perimeter bands 54 and 56 are not incorporated. Rather, only fingers 40 are provided with raised areas 118. In this manner, additional strengthening is provided only where needed most on fingers 40 and, thereby, decreasing manufacturing costs. More importantly, the forward ends 42 of fingers 40 are generally flat and do not increase in height until raised areas 118. This provides more "pointed" or "thinner" finger tips that are more easily received in the apertures 86.
While the invention has been described as having specific embodiments, it will be understood that it is capable of further modifications. This application is, therefore, intended to cover any variations, uses, or adaptations of the invention following the general principles thereof and including such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and fall within the limits of the appended claims. | 4y
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This application is a continuation of application Ser. No. 08/011,362, filed Jan. 29, 1993, now abandoned.
BACKGROUND OF THE INVENTION
High molecular weight polyesters prepared from diacids and dihydric alcohols have found extensive use in a variety of commercial products. Their excellent ductility and flexibility have found utility in fibers for apparel, carpeting, and tire cord. In addition, they are widely used in thin film applications such as magnetic tape and product packaging.
In recent years, high molecular weight polyesters have found increasing use as metal coatings, particularly in applications requiring a high degree of extensibility such as when coated metal sheeting is formed by drawing into cans or can ends that are used to package foods. However, these polymers suffer from a lack of solvent resistance since only their end groups are reactive with crosslinking agents. This fact, coupled with the very short oven bake conditions used in these types of applications, lead to very low levels of crosslinking in the baked film and poor resistance to solvents, particularly to those solvents that swell the film.
This lack of solvent resistance is addressed in European Patent Applications 0111986A2 and 0399108A1 which teach a two step process for preparing high molecular weight polyesters. A low molecular weight carboxylic acid terminated polyester prepolymer is first prepared and is then reacted with a diepoxide to further continue the chain building process. Each new polymer linkage formed between a carboxyl group of the prepolymer and an oxirane group of the epoxy resin consists of an ester group and a secondary alcohol. The alcohol serves as a locus for crosslinking which can be accomplished by thermally activated aminoplast or phenoplast curing agents. However, coatings made from such polymers may be subject to crazing, particularly after aging.
SUMMARY OF THE INVENTION
We have found that the protective coatings containing polymers as are thus prepared suffer from a loss in flexibility with time upon drawing, as evidenced by the degree of crazing that results from subjecting the coatings to drawing through the use of the well known reverse impact crazing test. The ability of the coating to resist crazing is reduced over time. We have found that this age to craze time is a strong function of polymer molecular weight and the crosslink density in the polymeric coating. For a given resistance to crazing after aging for a predetermined time, we have found that the lower the molecular weight of the polymer, the higher must be the crosslink density. However, if the polymer molecular weight is particularly low, the crosslink density required is so high that the coating material will no longer withstand the severe stresses introduced during the deformation of the metal.
In practical metal coating applications, we have found that best results are obtained when the number average molecular weight of the polyester polymer (that is, of the reaction product of the polyester prepolymer and the epoxy resin) is at least 7,000 and when the crosslink density is at a level sufficient to essentially prevent crazing during reverse impact for a period of aging at room temperature of 10 days following curing of the coating.
The reason for the loss over time of a coating's resistance to drawing is not entirely clear, but it appears to be related to a "freezing in" of free volume that occurs when the coating is subjected to rapid cooling after oven baking. Over time, at room temperature, the coating becomes more dense and less flexible as the free volume diminishes. When the molecular weight is sufficiently high to give extensive chain entanglements, or if the crosslink density is sufficiently high, the polymer chains are restricted in their motions so that the loss of free volume is minimized.
In our invention, we prepare a carboxyl functional prepolymer from a mixture containing one or more diacids and one or more dihydric alcohols using an excess of carboxyl groups over hydroxyl groups. After the hydroxyl groups are substantially reacted and the water of esterification is substantially removed, the carboxyl terminated prepolymer is reacted with a diepoxide under base catalysis using either a slight excess of epoxy groups or carboxyl groups depending on the type of terminal functional group considered most desirable for the application contemplated. The reaction between the acid group of the carboxyl functional prepolymer and an oxirane group of the epoxy resin produces an ester linkage and a secondary alcohol which may be used as the locus for subsequent crosslinking. To the resulting hydroxyl functional polymer is added sufficient crosslinking agent as to provide a high crosslink density in the product when cured.
Thus, in one embodiment, the invention relates to a method of forming a metal substrate bearing a draw-resistant coating, which comprises applying to the substrate a curable liquid coating composition and curing the coating by subjecting it to a predetermined temperature for a predetermined time. The liquid coating composition comprises a hydroxyl-functional block copolymer polyester reaction product of an epoxy resin and a carboxyl-functional polyester. A hydroxyl-reactive crosslinking agent is employed to provide a sufficiently high crosslink density so that the craze resistance of the coating as measured by reverse impact testing, when cured at the predetermined temperature and time, diminishes by no more than 20% when aged at room temperature for a ten day period or under equivalent aging conditions.
In another embodiment, the invention relates to a liquid coating composition for coating cans or other containers, the composition comprising a curable hydroxyl-functional block copolymer polyester reaction product of a 1,2-epoxy resin and a carboxyl-functional polyester resin, and a sufficient quantity of a hydroxyl-reactive crosslinking agent to provide at least 2.0, preferably from 2.5 to 10, and most preferably 3 to 7 equivalents of hydroxyl-reactive functional groups per hydroxyl equivalent of the block copolymer. Desirably, the hydroxyl-reactive crosslinking agent is present at a concentration of no more than 40% by weight based on the combined weight of the crosslinking agent and the polyester resin.
In yet another embodiment, the invention relates to a method of formulating a coating composition to produce craze-resistant coatings, comprising
a. providing aliquots of a curable hydroxyl-functional block copolymer polyester reaction product of a 1,2-epoxy resin and a carboxyl-functional polyester resin mixed with varying amounts of a crosslinking agent capable of reacting with hydroxyl functionality of the block copolymer;
b. subjecting cured coatings on metal of such aliquots to craze-resistance testing periodically over at least a ten day aging period at room temperature or the equivalent and determining the loss in craze resistance over said period; and
c. choosing for the coating composition an amount of said crosslinking agent corresponding to the aliquot yielding no more than 20% loss in craze resistance over said period.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While any diacid is useful in forming the polyester prepolymer reactant, satisfactory materials can be produced using such readily available acids as phthalic acid, adipic, succinic, sebacic or dimer acid. Similarly, common dihydric alcohols can be employed, including ethylene glycol, propylene glycol, butylene glycol, neopentyl glycol, cyclohexane diol, hexane diol, or the polyethers derived from these components. Polymerization occurs as a polycondensation reaction and is generally carded out at a temperature of from about 190° C. to about 250° C. and in an inert atmosphere of nitrogen, carbon dioxide or the like. The water formed in the condensation reaction may be removed by distillation under reduced pressure, azeotropic distillation, etc. The diacid is used in excess so as to provide the prepolymer with an acid number in the range of 20 to 100 and preferably 30 to 70, and a number average molecular weight in the range of 1100 to 5600. Esterification catalysts such as p-toluene sulfonic acid may be used.
Any diepoxide resin may be used, but the most useful for food packaging application are based on bisphenol A and epichlorohydrin, since these epoxy resin compounds are regulated in the United States by the Food and Drug Administration. The preferred epoxy resins are liquids at room temperature and have epoxy values (referred to as "EV" values in the mathematical treatment below) ranging from about 5.5 to about 1 milliequivalents of epoxide per gram.
The 1,2-diepoxide resin desirably has a number average molecular weight ranging from about 360 to about 3,600 and more preferably from about 360 to about 2000. A 1,2-diepoxide resin product of Shell Chemical Co. sold under the trademark Epon 828 having a number average molecular weight of approximately 385 and an epoxide equivalent weight of 185-192 has given good results. Low molecular weight epoxy resins such as Epon 828 may be chain extended by reaction with, e.g., Bisphenol A. In its preferred embodiment, the invention makes use of a 1,2-diepoxide resin having an epoxy functionality of 1.8 to 2 and an epoxy equivalent weight of 180 to 1800 and more particularly 180 to 1000.
The important properties of the block copolymer that need to be controlled include glass transition temperature (Tg), solubility parameter, viscosity and molecular weight. Solubility parameter and Tg are controlled by selecting components that are more or less polar, and that contribute hardness or softness to the polymer, as is well known to those skilled in the art. For example, selection of components having long aliphatic carbon chains lowers Tg, while selection of components having ring structures or bulky side chains raises Tg. Tg can be measured by well known techniques such as differential scanning calorimetry or torsion braid analysis. Solubility parameter is not normally measured, but components should be selected based on their known effect and selected to provide a value that is as far removed as practical from the solvents that will be contacted with the polymer during its useful life. For example, if water is the principal solvent, components should be selected having as low a value of solubility parameter as practicable. Thus, components that are water soluble should be used sparingly.
For metal coating applications requiring a high degree of extensibility, the Tg should be controlled below 100° C., preferably below 60° C. In general, the lower the Tg, the lower the probability of brittle failure of the coating during fabrication of the finished article but the more likely is the tendency of the coating to block (i.e., to adhere to another surface) when the coated metal is stacked in sheets or rolled as a coil. The lower limit of Tg thus is chosen to be sufficiently high so as to avoid blocking of the coating. Tg preferably is not lower than about 25 ° C.
The viscosity of the epoxy-polyester block copolymer is controlled principally by its weight average molecular weight. The weight average molecular weight is controlled by the number average molecular weight and the polydispersity of the molecular weight distribution. For linear polyesters, the weight average is about 2 times the number average.
Thus, in order to control the viscosity of linear polyesters, it is sufficient to control the number average molecular weight. Both the number and weight average molecular weights can be measured most conveniently by gel permeation chromatography.
The number average molecular weight of linear polyester-epoxy block copolymers used in the present invention may be calculated and controlled by use of the following definitions and relationships.
An=Acid number of polyester prepolymer, mg KOH/gm
Bn=Hydroxyl number of polyester prepolymer, mg KOH/gm
e=Average functionality of diepoxide
EV=Epoxy value of diepoxide, milliequivalents/gm
R=Ratio of acid groups in prepolymer to epoxy groups of the epoxy resin
P=Fractional conversion of acid or epoxy groups, whichever is present in lesser amount.
Mn=Number average molecular weight of block copolymer. ##EQU1##
In the calculation for Mn, the numerator represents the mass of ingredients in the charge while the denominator measures the end groups due to unreacted hydroxyl groups in the prepolymer, the unreactive groups present in the diepoxide, and the residual epoxy and acid groups left over due to incomplete reaction and inexact stoichiometry of the reactant charge.
As an example, consider a prepolymer having an acid number of 50 that is reacted with a diepoxide having an epoxy value (EV) of 5.35 meq/gm under stoichiometric conditions where R=1.0. The numerator in the molecular weight expression is equal to 130,692. Thus, if we desire a molecular weight (Mn) of 30,000, we must control the number of end groups to 130,692/30,000=4.36.
Proceeding further with this example, the target number of end groups can be achieved by controlling the hydroxyl number at a level of 2, by using a diepoxide of functionality 1.95, and by carrying out the reaction to 9955 completion. Substituting Bn=2.0, e=1.95 and p=0.99 into the expression for R=1 gives a value of 4.28 which is close to the value of 4.36 desired.
In general, the closer R is to 1.0, the lower the acid number of the polyester and the closer the functionality of the epoxy resin is to 2.0, then the higher the molecular weight of the polymer will be when all other conditions remain the same. While there is no theoretical upper limit on molecular weight, a practical limit of about 60,000 appears likely.
In metal coating applications, number average molecular weights of the block copolymer in the range of 7,000 to 30,000 are sufficient to meet the current requirements of extensibility and are consequently preferred so as to keep the amount of organic solvent required to a minimum.
The acid number of the prepolymer may be used to effect molecular weight as described above. In addition, the acid number may be used to control the amount of diepoxide required. This is evident from the following relationship which gives the weight fraction of diepoxide (W E ) in the polymer: ##EQU2## Thus for An=50, EV=5.35, and R=1.0, then W E =0.143.
Repeating the calculation for An=100, then W E =0.25. Similarly, the weight fraction diepoxide can be controlled by varying the epoxy value of the diepoxide. For example, for An=50, R=1.0, EV=1.0, then W E =0.47. Repeating the calculation for An=100, then W E =0.64. The values of An and EV employed are not critical in the present invention and thus are controlled by practical considerations. For ease of handling, liquid diepoxides are preferred. In the case of diepoxides based on bisphenol A and epichlorohydrin, an epoxy value of about 3 to about 5.5 is most convenient since this provides an easily handled liquid. The An value also is controlled by practical considerations. For example, if the targeted acid number is too low, the reaction time required to achieve a sufficiently low hydroxyl number (Bn) becomes excessively long and more difficult to achieve. If, on the other hand, the acid number is too high, then the amount of diepoxide required increases. Since the diepoxide component is generally more expensive than the polyester prepolymer component, the cost of the product may thus be increased. Another difficulty that is encountered through the use of prepolymers having high acid numbers is the difficulty of solubilizing the diacid reactant when using sparingly soluble acids such as terephthalic acid. Thus, the practical range of An lies between about 20 and 100, with the most preferred range between 30 and 70.
In addition to minimizing the residual hydroxyl groups present in the prepolymer, it is important to minimize the amount of water introduced into the reactor during the reaction of prepolymer with the diepoxide. While any method may be used to ensure that all materials are dry, it is most convenient to react any water present with a diacid anhydride such as phthalic anhydride. Diacid anhydrides are also useful to remove the last traces of hydroxyl groups present in the prepolymer. Careful attention to purity of materials, control of end groups during reaction, and elimination of water all lead to successful preparation of the high molecular weight polymers essential to the practice of this invention.
With regard to crosslink density, any of the well known hydroxyl-reactive curing resins can be used. Phenoplast and aminoplast curing agents are preferred, as are curing agents derived from phosphoric acid. Aminoplast resins are the condensation products of aldehydes such as formaldehyde, acetaldehyde, crotonaldehyde, and benzaldehyde with amino or amido group-containing substances such as urea, melamine and benzoguanamine. Useful alcohols include the monohydric alcohols such as methanol, ethanol, propanol, butanol, hexanol, benzyl alcohol, cyclohexanol, and ethoxyethanol. Urea-formaldehyde and esterified melamine-formaldehyde curing agents are preferred. Particularly preferred are the ethoxy methoxy melamine formaldehyde condensation products, exemplary of which is American Cyanamid's CYMEL® 325 curing agent. Phenoplast resins include the condensation products of aldehydes with phenol. Formaldehyde and acetaldehyde are preferred aldehydes. Various phenols can be employed such as phenol, cresol, p-phenylphenol, p-tert-butylphenol, p-tert-amylphenol, and cyclopentylphenol. As examples of other generally suitable curing agents are the blocked or non-blocked aliphatic, cycloaliphatic or aromatic di-, tri- or polyvalent isocyanates such as hexamethylene diisocyanate, cyclohexyl- 1,4-diisocyanate and the like. The level of curing agent required will depend on the type of curing agent, the time and temperature of the bake, and the molecular weight of the polymer.
Generally, curing agent levels will fall in the range of 8 to 40 wt. % of the combined weight of the epoxy-polyester block copolymer and the curing agent. As noted earlier, we have found that the crosslink density of the cured coating controls what we believe to be the loss of free volume upon aging, and that the crosslink density hence also is related to the ability of a coating of the invention to withstand subsequent drawing or other fabrication procedures to which coated substrates are subjected. Although a variety of metal drawing tests may be employed, we prefer a reverse impact test of 16 inch pounds performed at room temperature and as described generally in American Society for Testing Materials test designations ASTM D 1709 and ASTM D 3029. In this test, a weighted projectile having a hemispherical striking surface is dropped upon a coated metal panel that is supported coating side down on a suitable anvil. The coated test panels are aged at room temperature for various periods and are periodically subjected to the reverse impact test. The thus tested specimens exhibit a dome-shaped deformation where they are struck, and the coating at the apex of the dome is carefully visually examined and is rated from 1 to 10. A rating of 10 indicates that the coating at the apex is visually identical to the surrounding, unstressed coating. A rating of 1 indicates that the coating on the dome-shaped deformation has turned white due to crazing. A coating having a very slightly perceptible haze at the apex of the dome earns a rating of 9. The hydroxyl-reactive crosslinking agent is employed in sufficient quantity to provide a sufficiently high crosslink density so that the craze resistance of the cured coating as measured above by reverse impact testing, diminishes by no more than 20% when aged at room temperature for a ten day period or under equivalent time and temperature aging conditions. Preferably, the molar ratio of hydroxyl-reactive functional groups in the crosslinking agent to the reactive hydroxyl groups of the block copolymer is at least 2.0, preferably is in the range of 2.5 to 10 and most preferably ranges from 3 to 7.
For metal coating applications, the preferred embodiment of the present invention employs a carboxyl-functional prepolymer having an acid number between 20 and 100 most preferably between 30 and 70. The glass transition temperature of the block copolymer preferably is less than 60° C. and its number average molecular weight is between 7,000 and 60,000, and most preferably between 7,000 and 30,000. The coating composition includes a crosslinking agent at a concentration of from about 8 to about 40 wt % but in any event in sufficient concentration to provide a crosslink density high enough so that its resistance to crazing upon being drawn (as may be measured by reverse impact testing) decreases by no more than 20% over a ten day period at room temperature. Most preferably, the molar ratio of hydroxyl-reactive functional groups in the crosslinking agent to the reactive hydroxyl groups of the block copolymer is between 3 and 7. Further, the epoxide value of the epoxy resin precursor preferably is between 5.5 and 3.0.
The coating compositions of the invention may contain such common ingredients as pigment, solvent, fillers, dyes, leveling agents and other surface active agents and the like. In a preferred embodiment, the composition is free from pigment and other opacifying ingredients and forms a clear coating. The following examples are provided to illustrate the invention.
EXAMPLE #1
PREPARATION OF AN ACID END CAPPED POLYESTER PREPOLYMER
The components listed below were charged to a 5 liter round bottom reaction flask equipped with steam and water condensers, heating mantle, mechanical stirrer, thermometer, and inert gas source. The polycondensation reaction was carded out at 200°-240° C. under an inert nitrogen atmosphere. Water was removed by atmospheric distillation until reflux terminated. At this point the reactor contents were cooled to 200° C. and xylene, item #5, was charged to the reactor. Heat was reapplied and azeotropic distillation was continued until an acid value of about 50 was achieved and no further water could be removed from the reaction vessel.
______________________________________Item # MATERIAL GRAMS______________________________________1 Terephthalic Acid 14472 Isophthalic Acid 14473 Diethylene Glycol 16654 Fascat 4201.sup.1 65 Xylol 100 4665______________________________________ .sup.1 A product of ATOCHEM Company
Approximately 543 grams of distillate were removed from the reactor during the distillation procedure. The resultant polyester prepolymer had an acid number of 54.1 mg KOH/gm. and a determined solids of 94.7%.
EXAMPLE #2
PREPARATION OF A PREDOMINANTLY ACID END CAPPED POLYESTER-EPOXY COPOLYMER
The components listed below were charged to a 1 liter two piece reaction flask equipped with water condenser, heating mantle, mechanical stirrer, thermometer, and inert gas source.
______________________________________Item # MATERIAL GRAMS______________________________________1 Polyester Prepolymer 415 from Example #12 DER 383.sup.2 693 Tributylamine 24 Cyclohexanone 1705 Xylol 113______________________________________ .sup.2 A product of the Dow Chemical Company
The reactor contents were heated to 125° C. under an inert nitrogen atmosphere until essentially all epoxy was consumed and a final acid value of 5 or less was determined. The resultant polymer solution had a determined solids of 65.3%, a determined acid number of 3.1 mg KOH/gm., and final measured molecular weights of 45,600 (Mw) and 16,700 (Mn).
EXAMPLE #3
EXTENT OF CROSSLINKING VS. CRAZE RESISTANCE
The resin prepaxed in sample 2 was blended with several levels of Cymel 325 3 crosslinking agent and applied at 7.5 mg/in 2 to treated aluminum panels. The panels were baked for 9 seconds to a peak metal temperature of 450° F. and were immediately water quenched upon exiting the oven. The effect of crosslinking agent level is shown in the following table, in which the weight percent of the crosslinking agent is based on the combined weight of the crosslinking agent and the polyester resin:
______________________________________WT %CROSS-LINKINGAGENT CRAZE RATING ATPOLY- Mole 0 1 1 5 10MER Ratio W/% HRS HR DAY DAYS DAYS______________________________________100 0 0 9 4 5 2 295 1.17 5 10 9 7 4 390 2.35 10 10 10 9 7 685 3.5 15 10 10 10 8 880 4.7 20 10 10 10 9 9______________________________________
From the data above it is clear that for the crosslinking agent and cure condition chosen, the crosslinking agent level preferred is ≧15 %. | 4y
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BACKGROUND/SUMMARY
Vacuum is a medium for providing actuating force in some vehicles. For example, vacuum may be used to assist a driver to apply vehicle brakes. Vacuum may be sourced to actuators via an engine intake manifold, vacuum pump, or an ejector. Engine intake manifold vacuum may be a suitable vacuum source for naturally aspirated engines; however, there may be insufficient engine intake manifold vacuum for operating vacuum actuators when the engine is turbocharged. Therefore, vacuum may be provided for turbocharged engines via an ejector or a vacuum pump.
An ejector provides vacuum by way of providing a low pressure region in a flow path of a motive fluid. In some examples, the motive fluid may contain fuel vapors, untreated engine emissions, and/or engine crankcase vapors. If the ejector develops a leak, it may be possible for gases to enter the atmosphere. For example, an ejector leak may be manifested in a converging section, a diverging section, or a vacuum or suction section. Since pressure within the converging, diverging, and suction sections may vary significantly, it may require three or more sensors (e.g., a sensor in each section) to determine which, if any, ejector section is leaking. Consequently, it may be expensive and challenging to determine whether or not an ejector is leaking so that the engine control system can detect degradation and alert the driver and potentially take mitigating action. Further, it may be expensive or difficult to meet requirements of regulating agencies for determining if tubes that connect to an ejector have been disconnected.
The inventors herein have recognized the above-mentioned disadvantages and have developed a system for providing vacuum for a vehicle, comprising: an engine including an air intake passage; and a vacuum generating device including a motive fluid inlet section, a diverging discharge section positioned within the air intake passage, and a suction inlet.
By placing a diverging section of an ejector or a venturi within an engine air intake passage, it may be possible to avoid making measurements of the ejector diverging section to detect leaks in the diverging section since any leaks in the diverging section will be released into the closed boundary of the engine. Consequently, hydrocarbons or untreated exhaust gases entrained in the motive fluid, which provides vacuum via the ejector, are directed to engine cylinders where they may be combusted and then treated in the engine exhaust system. Additionally, a particular benefit of arranging an ejector within an engine air intake is that a disconnect or leak in the diverging section outlet may be unnecessary to detect because it is within the engine air intake. A connection at the diverging section is expensive to detect due to a requirement of additional pressure sensors within the diverging section.
The present description may provide several advantages. Specifically, the approach may reduce the need to monitor all sections of an ejector to diagnose the ejector for leaks. Further, the approach may reduce a number of sensors required to monitor an ejector for leaks. Further still, ejector leaks may be determined without adding any additional sensors to the vehicle system.
The above advantages and other advantages, and features of the present description will be readily apparent from the following Detailed Description when taken alone or in connection with the accompanying drawings.
It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a schematic depiction of an engine;
FIG. 2 shows a schematic depiction of a prior art air passage;
FIGS. 3-4 show example configurations of a vacuum providing device such that it may not be necessary to monitor a diverging section of the ejector or venturi;
FIG. 5 shows an example venturi or ejector; and
FIG. 6 shows an example method for leak testing a vacuum providing device.
DETAILED DESCRIPTION
The present description is related to providing vacuum to assists in actuator operation. FIG. 1 shows one example system for providing vacuum for a vehicle. FIG. 2 shows a prior art ejector system that may develop leaks to atmosphere. FIGS. 3 and 4 show example ejector or venturi systems whereby leaks to atmosphere via a diverging section of the ejector or venturi may be avoided. An example ejector and an example venturi are shown in FIGS. 5A and 5B . Finally, a method for diagnosing an ejector or venturi is shown in FIG. 6 .
Referring to FIG. 1 , internal combustion engine 10 , comprising a plurality of cylinders, one cylinder of which is shown in FIG. 1 , is controlled by electronic engine controller 12 . Engine 10 includes combustion chamber 30 and cylinder walls 32 with piston 36 positioned therein and connected to crankshaft 40 . Combustion chamber 30 is shown communicating with intake manifold 44 and exhaust manifold 48 via respective intake valve 52 and exhaust valve 54 . Each intake and exhaust valve may be operated by an intake cam 51 and an exhaust cam 53 . The position of intake cam 51 may be determined by intake cam sensor 55 . The position of exhaust cam 53 may be determined by exhaust cam sensor 57 .
Fuel injector 66 is shown positioned to inject fuel directly into cylinder 30 , which is known to those skilled in the art as direct injection. Alternatively, fuel may be injected to an intake port, which is known to those skilled in the art as port injection. Fuel injector 66 delivers liquid fuel in proportion to the pulse width of signal FPW from controller 12 . Fuel is delivered to fuel injector 66 by a fuel system (not shown) including a fuel tank, fuel pump, and fuel rail (not shown). Fuel injector 66 is supplied operating current from driver 68 which responds to controller 12 . In addition, intake manifold 44 is shown communicating with optional electronic throttle 62 which adjusts a position of throttle plate 64 to control air flow from intake boost chamber 46 .
Compressor 162 draws air from air intake passage 42 to supply boost chamber 46 . Exhaust gases spin turbine 164 which is coupled to compressor 162 via shaft 161 . Compressor bypass valve 158 may be electrically operated via a signal from controller 12 . Compressor bypass valve 158 allows pressurized air to be circulated back to the compressor inlet to limit boost pressure. Similarly, waste gate actuator 72 allows exhaust gases to bypass turbine 164 so that boost pressure can be controlled under varying operating conditions.
Vacuum is supplied to vehicle systems via vacuum providing device 24 . Compressor 162 provides compressed air as a motive fluid via converging section duct 31 to operate vacuum providing device 24 . The motive fluid is combined with air from vacuum reservoir 138 via vacuum port duct 37 and check valve 60 . Check valve 60 allows flow when the pressure produced via the ejector within vacuum port duct 37 is lower than the pressure within reservoir 138 . Mixed air exits at diverging section 33 . In some examples, vacuum reservoir 138 may be referred to as a vacuum system reservoir since it can supply vacuum throughout the vacuum system and since brake booster 140 may contain a vacuum reservoir too. Pressure in reservoir 138 may be monitored via vacuum reservoir pressure sensor 193 . Vacuum system reservoir 138 provides vacuum to brake booster 140 via check valve 65 . Check valve 65 allows air to enter vacuum system reservoir 138 from brake booster 140 and substantially prevents air from entering brake booster 140 from vacuum system reservoir 138 . Vacuum system reservoir 138 may also provide vacuum to other vacuum consumers such as turbocharger waste gate actuators, heating and ventilation actuators, driveline actuators (e.g., four wheel drive actuators), fuel vapor purging systems, engine crankcase ventilation, and fuel system leak testing systems. Check valve 61 limits air flow from secondary vacuum consumers (e.g., vacuum consumers other than the vehicle braking system) to vacuum system reservoir 138 . Brake booster 140 may include an internal vacuum reservoir, and it may amplify force provided by foot 152 via brake pedal 150 to master cylinder 148 for applying vehicle brakes (not shown).
Distributorless ignition system 88 provides an ignition spark to combustion chamber 30 via spark plug 92 in response to controller 12 . Universal Exhaust Gas Oxygen (UEGO) sensor 126 is shown coupled to exhaust manifold 48 upstream of catalytic converter 70 . Alternatively, a two-state exhaust gas oxygen sensor may be substituted for UEGO sensor 126 .
Converter 70 can include multiple catalyst bricks, in one example. In another example, multiple emission control devices, each with multiple bricks, can be used. Converter 70 can be a three-way type catalyst in one example.
Controller 12 is shown in FIG. 1 as a conventional microcomputer including: microprocessor unit 102 , input/output ports 104 , read-only memory 106 , random access memory 108 , keep alive memory 110 , and a conventional data bus. Controller 12 is shown receiving various signals from sensors coupled to engine 10 , in addition to those signals previously discussed, including: engine coolant temperature (ECT) from temperature sensor 112 coupled to cooling sleeve 114 ; a position sensor 134 coupled to an accelerator pedal 130 for sensing accelerator position adjusted by foot 132 ; a position sensor 154 coupled to brake pedal 150 for sensing brake pedal position; a knock sensor for determining ignition of end gases (not shown); a measurement of engine manifold pressure (MAP) from pressure sensor 121 coupled to intake manifold 44 ; a measurement of boost pressure from pressure sensor 122 coupled to boost chamber 46 ; an engine position sensor from a Hall effect sensor 118 sensing crankshaft 40 position; a measurement of air mass entering the engine from sensor 120 (e.g., a hot wire air flow meter); and a measurement of throttle position from sensor 58 . Barometric pressure may also be sensed (sensor not shown) for processing by controller 12 . Engine position sensor 118 produces a predetermined number of equally spaced pulses every revolution of the crankshaft from which engine speed (RPM) can be determined.
In some examples, the engine may be coupled to an electric motor/battery system in a hybrid vehicle. The hybrid vehicle may have a parallel configuration, series configuration, or variation or combinations thereof. Further, in some examples, other engine configurations may be employed, for example a diesel engine.
During operation, each cylinder within engine 10 typically undergoes a four stroke cycle: the cycle includes the intake stroke, compression stroke, expansion stroke, and exhaust stroke. During the intake stroke, generally, the exhaust valve 54 closes and intake valve 52 opens. Air is introduced into combustion chamber 30 via intake manifold 44 , and piston 36 moves to the bottom of the cylinder so as to increase the volume within combustion chamber 30 . The position at which piston 36 is near the bottom of the cylinder and at the end of its stroke (e.g. when combustion chamber 30 is at its largest volume) is typically referred to by those of skill in the art as bottom dead center (BDC). During the compression stroke, intake valve 52 and exhaust valve 54 are closed. Piston 36 moves toward the cylinder head so as to compress the air within combustion chamber 30 . The point at which piston 36 is at the end of its stroke and closest to the cylinder head (e.g. when combustion chamber 30 is at its smallest volume) is typically referred to by those of skill in the art as top dead center (TDC). In a process hereinafter referred to as injection, fuel is introduced into the combustion chamber. In a process hereinafter referred to as ignition, the injected fuel is ignited by known ignition means such as spark plug 92 , resulting in combustion. During the expansion stroke, the expanding gases push piston 36 back to BDC. Crankshaft 40 converts piston movement into a rotational torque of the rotary shaft. Finally, during the exhaust stroke, the exhaust valve 54 opens to release the combusted air-fuel mixture to exhaust manifold 48 and the piston returns to TDC. Note that the above is described merely as an example, and that intake and exhaust valve opening and/or closing timings may vary, such as to provide positive or negative valve overlap, late intake valve closing, or various other examples.
Referring now to FIG. 2 , a schematic depiction of a prior art engine air inlet passage is shown. Engine air inlet passage 42 includes compressor 162 and boost chamber 46 . Vacuum providing device 24 includes a converging section 35 , a throat 201 , a diverging section 33 , and a vacuum port 214 . A converging section duct or conduit 31 connects boost chamber 46 to converging section 35 of vacuum providing device 24 and provides for fluidic communication between boost chamber 46 and vacuum producing device 24 . Vacuum port duct 37 begins at the vacuum port 214 in throat 37 and is connected to vacuum reservoir 138 via check valve 60 . Diverging section 33 is in communication with engine air inlet passage 42 via diverging section duct or conduit 210 . Diverging section duct 210 provides fluidic communication between diverging section 33 and engine air inlet 42 .
The system of FIG. 2 operates as follows. Air flows through compressor 162 in the direction of the arrows. Boost chamber 46 holds air that is at a higher pressure than locations upstream of compressor 162 . Air exits boost chamber 46 and proceeds to engine 10 or enters converging section duct 31 leading to vacuum providing device 24 . Air that enters converging section duct 31 accelerates through throat 201 where air pressure drops to provide a vacuum that draws air from vacuum port duct 37 via vacuum port 214 . Air flows from vacuum reservoir 138 to throat 201 of vacuum providing device 24 via check valve 60 . Next, air flows through diverging section 33 and returns to engine air intake 42 . Converging section 35 and diverging section 33 are surrounded by atmosphere. A leak may occur in converging section 35 or diverging section 33 such that air and gases within vacuum providing device 24 escape to atmosphere.
In this system, if diverging section 33 is disconnected from engine air intake 42 , it creates an engine intake leak. This engine intake leak may be detected using a compressor inlet pressure (CIP) sensor, crankcase pressure sensor, or a crankcase vent tube pressure sensor. For example, at high engine air flows, an air leak around the air filter results in failure to detect an air pressure drop across the air cleaner, and some undesirable gases may be emitted to atmosphere. However, if a small diameter tube is used to couple diverging section 33 to engine air intake 42 , a disconnect at either end of the duct 210 remains undetectable. The use of a large diameter (e.g. 12 mm) duct 210 at 42 would solve diagnose-ability at the connection neat the engine air intake 42 . On the other hand, use of a large diameter tube from 33 to 42 solves the detection issue. However, the large diameter connectors and tubes create a detectable problem instead of a non-detectable one (e.g., false positive leaks).
Regarding leaks of vacuum, if a disconnected duct or leak occurs between check valve 60 and vacuum reservoir 138 , the leak may be determined at this location via a vacuum check at the vacuum user end. For example, a pressure that is higher than is expected in vacuum reservoir 138 may be determined to be a leak.
Regarding leaks of motive fluid supplied to the vacuum producing device 24 , if a disconnected duct or leak occurs between boost chamber 46 and converging section 35 along duct 212 , such a leak may be determined from an inability to build expected compressor outlet pressure.
Finally, if the disconnect occurs between throat 201 and vacuum inlet 37 , it can be diagnosed as failure to increase vacuum in the item in which vacuum is to be created.
Referring now to FIG. 3 , a first example configuration of a vacuum providing device such that it may not be necessary to monitor a diverging section for leaks is shown. Engine air inlet passage 42 includes compressor 162 and boost chamber 46 along its length. Vacuum providing device 24 includes a converging section 35 , a throat 201 , a diverging section 33 , and a vacuum port 201 . A converging section duct or conduit 31 connects boost chamber 46 to converging section 35 of vacuum providing device 24 , and the converging section duct 31 provides for fluidic communication between boost chamber 46 and vacuum producing device 24 . Vacuum port 214 begins at a low pressure region of throat 37 and vacuum port duct 37 connects vacuum port 214 to vacuum reservoir 138 via check valve 60 . Vacuum port duct or conduit 214 provides connectivity and fluidic communication between vacuum port 214 and check valve 60 . Diverging section 33 is positioned within engine air inlet passage 42 so that via diverging section duct or conduit 210 is eliminated.
The system of FIG. 3 operates as follows. Air flows in engine air inlet passage 42 in the direction of the arrows. Compressor 162 receives air at compressor inlet 399 and compresses air in boost chamber 46 . Air may exit boost chamber 46 to engine 10 or vacuum providing device 24 . Boost chamber 46 includes outlet port 342 where air leaves boost chamber 46 to enter converging section duct 31 leading to vacuum providing device 24 . Valve 362 is positioned within boost chamber 46 and it controls air flow through vacuum providing device 24 . Alternatively, valve 362 may be located within engine air inlet passage 42 as indicated by the dashed lines. Valve 362 may be variably adjusted to a plurality of positions between full open and full close to adjust air flow through vacuum providing device 24 . Converging section 35 directs compressed air to throat 201 . In some examples, converging section 35 may also be described as a motive fluid inlet. Air reenters engine air inlet passage 42 via inlet port 340 . Air accelerates through throat 201 causing a pressure drop, thereby providing a vacuum source. Vacuum port 214 opens up to a low pressure region in throat 201 . Air may be drawn from vacuum reservoir 138 via check valve 60 to throat 210 . Air from reservoir 138 and air from boost chamber 46 combine in diverging section 33 . In this example, diverging section 33 and engine air inlet passage 42 share wall 320 . Atmosphere surrounds engine air inlet passage 42 and converging section 35 . Diverging section releases motive fluid (e.g., air) and air from vacuum reservoir 138 directly into engine intake passage 42 . Air must pass through wall 320 of engine air inlet passage 42 to exit diverging section 33 . Thus, the engine air inlet passage 42 may provide a barrier between diverging section 33 and atmosphere. Consequently, if diverging section 33 develops a leak on the interior side of engine air inlet passage 42 , the leak may be constrained by engine air inlet passage 42 . However, if a leak develops in wall 320 diverging section 33 , undesirable gases may be released to atmosphere from diverging section 33 .
Referring now to FIG. 4 , an alternative example vacuum providing device is shown. Engine air inlet passage 42 includes compressor 162 and boost chamber 46 along its length. Air flows in engine air inlet passage 42 in the direction of the arrows. Compressor 162 receives air at compressor inlet 399 and compresses air in boost chamber 46 . Air may exit boost chamber 46 to engine 10 or vacuum providing device 24 . Boost chamber 46 includes outlet port 342 where air leaves boost chamber 46 to enter converging section duct 31 . Valve 362 controls air flow through vacuum providing device 24 and it is located within boost chamber 46 so as to provide a seal between boost chamber 46 and converging section duct 31 . Thus, valve 362 may be closed to prevent air from leaks in converging section duct 31 from escaping to atmosphere. Alternatively, valve 362 may be located within engine air inlet 42 . Valve 362 may be variably adjusted to a plurality of positions between full open and full close to adjust air flow through vacuum providing device 24 . Converging section 35 directs compressed air to throat 201 . In some examples, converging section 35 may also be described as a motive fluid inlet. Air reenters engine air inlet passage 42 via inlet port 340 . Air accelerates through throat 201 causing a pressure drop, thereby providing a vacuum source at vacuum port 214 . Vacuum port 214 opens up to a low pressure region in throat 210 . Air may be drawn from vacuum reservoir 138 via check valve 60 to throat 210 . Air from reservoir 138 and air from boost chamber 46 combine in diverging section 33 . In this example, diverging section 33 and engine air inlet passage 42 do not share a common wall. Rather, wall 402 surrounds at least a portion of diverging section 33 and the diverging section 33 of the vacuum providing device 24 is completely enclosed within the engine air inlet passage 42 . Atmosphere surrounds engine air inlet passage 42 and converging section 35 . Diverging section releases motive fluid (e.g., air) and air from vacuum reservoir 138 directly into engine air inlet passage 42 . Air may exit all portions of diverging section 33 and still be retained in engine air inlet passage 42 . Thus, the engine air inlet passage 42 completely surrounds diverging section 33 to isolate it form atmosphere. In other words, diverging section 33 is completely within air intake passage 42 . Consequently, if diverging section 33 develops a leak, the leak may be constrained from exiting to atmosphere by engine air inlet passage 42 .
Referring now to FIG. 5 , a first example of a vacuum providing device 24 is shown. In this example, vacuum providing device 24 takes the form of a venturi. Vacuum providing device 24 includes converging section 35 (e.g., a motive fluid inlet) where motive fluid arrives at a higher first pressure and is accelerated into throat 201 . A second pressure region at a lower pressure than the higher first pressure forms in throat 210 so that air may be drawn into vacuum providing device 24 via vacuum port 214 . Motive fluid and air combine and exit vacuum providing device 24 via diverging section 33 . In diverging section 33 , pressure recovers to a higher third pressure which is a higher pressure than the pressure in the second pressure region.
It should be noted that the presence of valve 362 presents opportunities to improve diagnoses of a disconnected duct as compared to locating valve 362 external to boost chamber 46 or engine air inlet 42 . For example, if valve 362 is housed in boost chamber 46 , valve 362 may be opened or closed during boost conditions. If a disconnected duct is present at converging section 35 , a compressor loss may occur when the valve 362 is open, but not when it is closed. If valve 362 is housed within engine air inlet 42 , a lack of CIP vacuum at high air flow may occur if valve 362 is open, but not when valve 362 is closed.
Thus, the system of FIGS. 1 and 3 - 5 B provides for a system that provides vacuum for a vehicle, comprising: an engine including an air intake passage; and a vacuum generating device including a motive fluid inlet section, a diverging discharge section positioned within the air intake passage, and a suction inlet. The system includes where the vacuum generating device is an ejector. The system includes where the vacuum generating device is a venturi.
In some examples, the system further comprises an air compressor positioned along the air intake passage and providing air to the motive fluid inlet. The system includes where the diverging discharge section is positioned upstream of an air inlet of the air compressor. The system includes where the suction inlet is in pneumatic communication with a vacuum reservoir that supplies vacuum to vacuum consumers of the vehicle. The system further comprises a controller, the controller including non-transitory executable instructions to diagnose leaks of the vacuum generating device. The system includes where the discharge section form a portion of a wall of the air intake passage.
The system of FIGS. 1 and 3 - 5 B provides for a system that provides vacuum for a vehicle, comprising: an engine including an air intake passage; a vacuum generating device including a motive fluid inlet section, a diverging discharge section completely positioned within the air intake passage, a throat section completely positioned within the air intake passage, and a suction inlet; and a controller including non-transitory executable instructions to diagnose leaks of the vacuum generating device. The system includes where the controller includes instructions for determining leaks in the motive fluid inlet section and suction, the controller not including instructions for determining leaks in the discharge section. The system includes where the controller includes additional instructions for determining leaks in the air intake passage instead of the discharge section.
In some examples, the system further comprises a compressor positioned along the air intake passage, and where the motive fluid inlet section extends from upstream of the compressor to downstream of the compressor. The system further comprises a valve positioned along a length of the motive fluid inlet section. The system includes where the vacuum generating device is an ejector or a venture.
Referring now to FIG. 6 , a method for leak testing a vacuum providing device is shown. The method of FIG. 6 may be stored in non-transitory memory as executable instructions of controller 12 in FIG. 1 . The method of FIG. 6 may be applied to a system as described in FIGS. 1 , 3 , 4 , 5 A, and 5 B.
At 602 , method 600 judges whether or not to diagnose a vacuum providing device for leaks. The vacuum providing device may be an ejector or a venturi. The vacuum providing device may be diagnosed for leaks when selected conditions are met. For example, method 600 may judge to perform a diagnostic leak test after a threshold amount of time between vacuum device leak tests has been exceeded. In another example, a diagnostic leak test of the vacuum device may be performed when vacuum is not being produced at a desired rate. If method 600 judges that a diagnostic vacuum device leak test is to be performed, the answer is yes and method 600 proceeds to 604 . Otherwise, the answer is no and method 600 proceeds to exit.
At 604 , method 600 determines leakage at a suction inlet of the vacuum providing device and at a vacuum line between the vacuum providing device and a vacuum reservoir. In one example, a valve is opened to start flow of a motive fluid through the vacuum providing device. The motive fluid may be air and the air may be compressed via a turbocharger. All vacuum consumers are commanded to a closed state and pressure within the vacuum reservoir is sensed by a pressure sensor. Air is drawn from the vacuum reservoir to the vacuum providing device, provided limited leakage is present. The motive fluid is returned to the engine with air from the vacuum reservoir at a location upstream of the compressor via a diverging discharge section of a vacuum generating device positioned within an engine air inlet. If less than a threshold amount of vacuum develops in the vacuum reservoir, it may be determined that there is a leak at the suction port of the vacuum providing device. Method 600 proceeds to 606 after leak testing of the suction port is performed.
At 606 , method 600 determines leakage of a converging section of a vacuum providing device. In one example, a compressor is operated at a steady speed while throttle position is constant and when engine speed is constant. If less than a desired pressure develops downstream of the compressor, it may be determined that there is a leak in the converging section of the vacuum providing device. Further, in some examples, two conditions including pressure less than a threshold downstream of the compressor and vacuum being provided at less than a threshold rate may be conditions for determining leakage of a converging section of a vacuum providing device. Note that for some systems which include an ejector, the converging section may include a chest area of the ejector. Method 600 proceeds to 608 .
Note that the suction inlet and converging section may be outside of the engine air inlet so that any leaks in the suction inlet and converging section are exposed to atmosphere.
At 608 , method 600 may determine leakage of a diverging section of a vacuum providing device. Alternatively, in some examples method 600 may not provide instructions for determining leakage of the diverging section of the vacuum providing device because the vacuum providing device is positioned within the engine air intake inlet as shown in FIGS. 3 and 4 . Since the vacuum providing device diverging section is within the engine air inlet passage, leaks are directed from the vacuum providing device diverging discharge section to the engine air inlet passage. If method 600 includes instructions for determining leakage in the vacuum providing device diverging section, a pressure or flow rate in the engine intake inlet upstream of the compressor may be compared to a threshold engine intake pressure or flow rate at constant engine speed, constant boost pressure chamber pressure, constant throttle position, and constant compressor flow. If the engine intake pressure is less than a threshold pressure or if the engine intake flow rate is greater than a threshold flow rate, method 600 may judge that a leak in the vacuum providing device diverging section is present. In this way, method 600 determines leaks in an air intake passage for determining leaks from the discharge section to atmosphere.
If a leak is determined at 604 , 606 , or 608 , method 600 provides an indication to the driver to service the engine. Further, method 600 may store leak information in memory. Method 600 exits after performing the leak tests.
Thus, the method of FIG. 6 provides a method for providing vacuum for a vehicle, comprising: drawing an amount of air from a vacuum reservoir via a low pressure region of a vacuum generating device; and supplying the amount of air to an engine air intake passage via a diverging discharge section of the vacuum generating device positioned within the engine air intake passage. The method further comprises diagnosing leaks from the vacuum generating device that are outside of the engine air intake passage. The method further comprises providing motive fluid to the vacuum generating device via a compressor. The method includes where the amount of air is provided at a location upstream of an inlet of the compressor. The method further comprises directing leaks from the diverging discharge section to the engine air intake passage. The method includes where the amount of air is combined with air originating from the engine air intake system before being expelled from the diverging discharge section.
As will be appreciated by one of ordinary skill in the art, the methods described in FIG. 6 may represent one or more of any number of processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various steps or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Likewise, the order of processing is not necessarily required to achieve the objects, features, and advantages described herein, but is provided for ease of illustration and description. Although not explicitly illustrated, one of ordinary skill in the art will recognize that one or more of the illustrated steps or functions may be repeatedly performed depending on the particular strategy being used. In addition, the terms aspirator or venturi may be substituted for ejector since the devices may perform in a similar manner.
This concludes the description. The reading of it by those skilled in the art would bring to mind many alterations and modifications without departing from the spirit and the scope of the description. For example, single cylinder, I2, I3, I4, I5, V6, V8, V10, V12 and V16 engines operating in natural gas, gasoline, diesel, or alternative fuel configurations could use the present description to advantage. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to treatments for the disposal of pesticides in wastewater. More particularly, this invention relates to a method for decomposing 2-chloro-4-(ethylamino)-6-(isopropylamino)-s-triazine, hereinafter referred to as "atrazine" in wastewater solutions.
2. Description of the Prior Art
Atrazine is one of the most widely used herbicides in the United States. Annual production was estimated at 35,913 metric tons in 1982. Atrazine has been detected in groundwater in the parts per billion (ppb) range.
Safe disposal of herbicide wastewater containing atrazine compounds, and compounds related thereto, is a major problem for the farmer, commercial applicator, or small-scale formulator. Improper herbicide wastewater disposal is a significant contributing factor to groundwater contamination. Consequently, there exists a need for a simple, low-cost, and versatile system for the disposal of atrazine which maybe used by the low-level herbicide user.
Wastewater disposal treatments currently being investigated in the United States include (1) rinsewater recycling; (2) granular carbon absorption; (3) UV-ozonation; (4) small-scale incineration; (5) solar photo-decomposition; (6) chemical degradation; (7) evaporation, photodegradation and biodegradation in containment devices; (8) genetically engineered products; (9) leach fields; (10) acid and alkaline trickling filter systems; (11) organic matrix adsorption and microbial degradation; (12) and evaporation and biological treatment with wicks. Although most of these technologies are still in the experimental stage, they show little promise because they are costly and slow, often producing inconsistent results or having a limited applicability. Further, techniques such as wastewater volume reduction by rinsewater recycling and granular carbon absorption are disadvantageous because they require additional steps to decompose the pesticide or to recover carbon sources.
SUMMARY OF THE INVENTION
We have now developed a system which is highly effective to decompose atrazine in aqueous solutions. In accordance with the process of the invention, the destruction of atrazine is accomplished by ozonation of the atrazine molecule in an aqueous medium followed by microbial soil degradation of the ozonated product. The system of the invention is simple, economical and practical for the on-site degradation of atrazine in wastewater solutions, thereby preventing the movement of the herbicide into groundwater.
Accordingly, it is an object of the present invention to provide a process which is highly effective to decompose atrazine in aqueous wastewater solutions.
It is also an object of the invention to provide a simple and economical atrazine wastewater disposal system which is readily adaptable to the on-site disposal of the herbicide.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic view of a mobile, 2-step ozone generator/soil herbicide wastewater disposal system which is useful to degrade atrazine in aqueous solutions in a single system using the process of the invention.
FIG. 2 outlines the metabolism of 2-chloro-4,6-diamino-s-triazine in a soil column not inoculated with and a soil column inoculated with Pseudomonas sp., Strain A.
FIG. 3 outlines comparative rates of ozonation of atrazine in aqueous solutions buffered to pH 8 and pH 10, respectively.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the process of the invention, atrazine is chemically oxidized with ozone to produce a more polar s-triazine molecule which is more susceptible to microbial metabolism than the unoxidized atrazine molecule. Ozonation of atrazine appears to proceed by the addition of oxygen to the alkylamino group followed by dealkylation to form the diamino-s-triazine molecule, i.e. 2-chloro-4,6-diamino-s-triazine. Subsequently, the diamino-s-triazine molecule is metabolized using a selected soil microorganism, i.e. a bacterium of the genus Pseudomonas, to the dihydroxy compound which spontaneously dechlorinates. the resulting cyanuric acid is readily metabolized to carbon dioxide and ammonia by indigenous microorganisms present in organic soils. The proposed mechanism for the process of the invention is as follows: ##STR1## The amount of ozone useful in the invention process is any amount sufficient to dealkylate the atrazine molecule. As will be obvious to one skilled in the chemical arts, the rate of oxidation will be determined by the rate-determinating step, i.e., the rate of transfer of gaseous ozone into the aqueous phase. Consequently, the rate of oxidation will vary depending upon such factors as (1) the amount of organic material dissolved in the aqueous solution; (2) the concentration of ozone used; (3) the gas pressure used during ozonation; (3) the reaction temperature; (4) the degree or rate of mixing of the reaction mixture; (5) the bubble size of ozone gas; (6) the contact time between the ozone gas and the wastewater solution; and (7) and the like. For example, to provide sufficient contact time between the ozone gas bubble and the herbicide wastewater solution, the water depth should be within the range of about 0.9 to 5.5 meters. To preserve ease of movement of the decontaminating devise, the water depth of the reaction vessel is preferably 0.9 to 2.0 meters.
To further enhance the rate of oxidation in the invention process, the pH of the wastewater solution maybe adjusted to about pH 8 to pH 10.8, preferably about pH 10 to 10.8. The rate of oxidization may also =accelerated by the addition of hydrogen peroxide (H 2 O 2 ) to the herbicide wastewater solution. Preferably, hydrogen peroxide is added in an amount of from about 20 to 100 mg/l.
Metabolism of the 2-chloro-4,6-diamino-triazine is accomplished in a organic-rich soil. i.e. a soil consisting of from about 10 to 20 percent of organic matter, inoculated with a bacterium of the genus Pseudomonas, preferably Pseudomonas sp., Strain A or Pseudomonas sp., Strain D. Strain A and Strain D maybe obtained from the culture collection at the North Regional Research Center, U.S. Department of Agriculture, Peoria, Illinois, 61604 under the accession numbers NRRIB-12227 and NRRLB-12228, respectively. Growth conditions and nutrient requirements for Strain A and Strain D were the same as described in Cook, A. M., "Biodegradation of s-triazine xenobiotics", FEMS Microbiol. Rev., 46: 93-16 (1987).
The process of the invention is preferably accomplished using the wastewater disposal system as shown in FIG. I. In general, the system comprises a means 1 for generating ozone; a reaction vessel 3 operatively associated with said means for generating ozone; a biologically-active soil column 6 operatively associated with said reaction vessel: and a means 8 for collecting the biodegraded, pre-ozonated products exiting from the system. The disposal system further comprises a means 2 for dispersing ozone within the wastewater solution 4 in the reaction vessel, and a means 5 for transporting the ozonated wastewater solution from the reaction vessel to the soil column. Optionally, the decontamination unit as shown in FIG. I provides a means 7 for recirculating treated atrazine wastewater solution within the decontamination unit for successive treatments.
The invention is further demonstrated by the following example which is intended only to further illustrate the invention and not to limit the scope of the invention as defined by the claims.
EXAMPLE I
The effectiveness of the hybrid chemical-biological process of the invention to degrade atriazine in aqueous solutions was demonstrated. The two-step process was performed in a single system using the device as shown in FIG. I.
Atrazine was obtained from CIBA-GEIGY Corp., Greensboro, North Carolina 27419 under the tradename "Aatrex" which contains 480 g/L of pure atrazine.
23.75 ml of Aatrex (containing 480 mg atrazine/mL) was added to 114 L of tap water resulting in a 100 mg/L atrazine solution. 555 g of sodium carbonate monohydrate (4.5 moles) was added to the atrazine solution and the solution was mixed by stirring. The pH of the solution was 10.8. Ozonation was carried out at maximum ozone output. The ozone generator was operated at 4 Axps, 10 PSI, and an air flow of 25-30 SCFH producing ozone at a rate of approximately 600 mg/min. The reaction was carried out until 2-chloro-4,6-diamino-s-triazine accumulated. This occurred at 12 hours as determined by high pressure liquid chromatography.
The ozonated solution was adjusted to pH 7.2 by the addition of 600 ml of concentrated hydrochloric acid. The solution was supplemented with 4 L of a 0.5 M solution of potassium phosphate buffer, pH 7, resulting in 17 mM potassium phosphate. 615.6 g of succinate was added resulting in approximately 20 mM succinate. The solution was also supplemented with trace metals.
Soil metabolism was conducted in a Sassafras silt loam (14% organic matter, pH 4.2, sand silt and clay contents of 56%, 20% and 24%, respectively, and a moisture content of 57% at 1/3 bar) obtained from Salisbury, Maryland. A soil column was preconditioned by circulating 114 L of 20 mM phosphate buffer pH 7 for 48 hours at an initial rate of 1 L/minute. Following equilibration, the buffer was removed and replaced with 114 L of 20 mM phosphate buffer pH 7 containing 10 mM lactate, 1.5 mM ammonium sulfate, and trace metals as described in Cook and Hutter (1981). 2 L of Pseudomonas sp. Strain A (2.75×10 11 CFU/ml) were added to the soil column and allowed to circulate for 48 hours prior to the addition of a second inoculum of 2 L of Pseudomonas sp. Strain A containing 1.5×10 12 CFU/ml. The second inoculum was allowed to circulate for 24 h prior to the addition of the ozonated atrazine.
CFU's were calculated by streaking dilutions of the inoculi on purified agar plates containing 10 mM phosphate buffer pH 7, 10 mM succinate and 0.5 mM ammelide allowing for 48 hours growth at 37°0C. and counting CFU's on the plate. No attempts were made to calculate the rate and/or extent of colonization in the soil column. The control was circulated through a soil column not preconditioned nor inoculated with Pseudomonas sp. Strain A.
The 114 L of ozonated atrazine solution was fortified to 20 mM succinate and trace metals prior to addition and circulation through the soil column. The solution was continuously circulated through the soil column at a flow rate of 9-10 L/hour using a drum pump for application and a peristaltic pump to return the solution to the reaction vessel. The solution in the reaction vessel was continuously aerated using the oilless air compressor as an air source. The solution was circulated through the soil column until no s-triazine could be detected by HPLC. Results are recorded in FIG. II.
Microbial metabolism of ozonated atrazine in soil inoculated with Pseudomonas sp., Strain A was very rapid. As shown in FIG. II, essentially over 90% of chlorodiamino-s-triazine of ozonated atrazine was degraded after 4 days. Indigenous soil microrganisms degraded the ozonated atrazine more slowly achieving only about 25% degradation after 28 days.
EXAMPLE II
The effect of pH to enhance the rate of ozonation of atrazine was demonstrated.
Ozonation was carried out using the procedure as described in Example 1 using 2 samples of 100 mg/L of formulated solution of atrazine. The samples were respectively buffered at pH 8.0 and pH 10. The loss of atrazine was measured in accordance with the procedure in Example I. Results are recorded in FIG. III.
As shown in FIG. III, more than 99% loss of the parent atrazine molecule occurred in 6 hours at pH 10, while the same loss level was achieved at 26 hours at pH 8.
It is understood that modifications and variations may be made to the foregoing disclosure 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 present invention relates to a fuel assembly for a nuclear reactor using a coolant such as a liquid metal, and particularly to a fuel assembly which is configured to store and hold a plurality of fuel pins in a wrapper tube by using grids and liner tubes and which suppresses an unnecessary flow of the coolant in an outer circumferential side in the wrapper tube and increases the flow volume of the coolant passing through interiorly disposed ones of the fuel pins to thereby increase the core power.
2. Related Art
Generally, in a nuclear reactor, a fuel assembly is supported in a reactor core while being attached to a support member. In a nuclear reactor using a coolant such as a liquid metal, an electromagnetic pump is used as a drive source to circulate the coolant around a plurality of fuel pins included in the fuel assembly supported in the reactor core. In this case, if the nuclear reactor is small-sized, the fuel assembly is configured to store the fuel pins in a wrapper tube to enable the circulation of the coolant with no need for the drive source. The wrapper tube is configured to include an entrance nozzle at a lower end thereof for introducing the coolant, and an operation handling head at an upper end thereof. The wrapper tube includes therein grids for supporting the fuel pins in the radial direction of the wrapper tube, and liner tubes inserted in the wrapper tube for fixedly holding the respective grids in the axial direction of the wrapper tube. The intervals in the radial direction of the fuel pins are kept by the grids. Meanwhile, the intervals in the axial direction of the grids are kept by a tie rod, the liner tubes, or the like (see Japanese Unexamined Patent Application Publication No. 6-174882, for example).
FIGS. 23 and 24 illustrate the configuration of this type of conventional fuel assembly. In the figures, a plurality of fuel pins 101 are stored in a wrapper tube 103 , with the pin intervals of the fuel pins 101 being kept by grids 102 . Each of the fuel pins 101 is fixed at a lower portion thereof by a lower pin support plate 105 and at an upper portion thereof by an upper pin support plate 106 . The coolant such as a liquid metal flows in from a coolant inlet 108 of an entrance nozzle 104 and flows out from a coolant outlet 109 of a handling head 107 .
In the thus configured fuel assembly, as illustrated in FIG. 25 , each of the grids 102 , which has a low pressure drop, includes a grid frame 102 a provided with a multitude of ring-shaped pin support members 110 . As illustrated in FIG. 26 , for example, each of the pin support members 110 is provided with three dimples 110 a on the inside thereof such that the circumference of the corresponding fuel pin 101 is three-point supported, for example, by the dimples 110 a.
FIG. 27 illustrates a deformation state in which the wrapper tube 103 is expanded by the thermal expansion. That is, the wrapper tube 103 , the basic form of which is a regular hexagon as indicated by a virtual line in FIG. 27 , is expanded when used due to the irradiation deformation and is deformed so as to expand toward the outer circumference thereof as indicated by a solid line. Conventionally, to cope with such deformation, liner tubes each formed by a thin hexagonal tube are provided outside a fuel bundle such that the liner tubes and the grids are alternately stacked. Thereby, the intervals in the axial direction of the grids are kept.
In such a configuration, however, the flow passage area around the fuel bundle is large. Thus, the cladding temperature in a central area of the fuel bundle becomes relatively high in some cases. Therefore, there arises a need to keep the cladding temperature equal to or lower than a cladding temperature limit. As a result, the thermal efficiency is decreased.
To address this issue, the inventors of the subject application have proposed a technique for reducing the cladding temperature, in which followers each having a triangular cross section are provided to reduce the flow passage area of a bundle edge sub-channel in a core heat generation unit for preventing a peripheral flow. That is, according to the technique, the liner tubes are provided with peripheral flow preventing projections to suppress the occurrence of the above-described phenomenon (see “Development of Densely. Packed and Low-Pressure-Drop Fuel Assembly for Non-Refueling Core (3),” 2004 Fall Meeting Preliminary Proceedings 307 of the Atomic Energy Society of Japan, for example).
Meanwhile, in the above-described conventional configuration, the liner tubes and the grids are stacked and may be mutually misaligned in the radial direction. If the liner tubes and the grids are misaligned in the radial direction, an opening may be formed between the wrapper tube and the liner tubes to allow the coolant to flow from inside the liner tubes into the space on the wrapper tube side as a waste flow.
Further, in the conventional fuel assembly, the bulging deformation occurs in the wrapper tube by the irradiation creep due to the inner pressure of the wrapper tube. It is therefore possible in the expanded portion that the flow passage area of a peripheral region around the fuel bundle is increased while the flow volume of the coolant in the central area of the fuel bundle is reduced, and thus that the cladding temperature is increased. It is also possible that the liner tubes are similarly expanded due to the inner pressure applied thereto.
SUMMARY OF THE INVENTION
The present invention has been made in light of the above-described circumferences, and it is an object of the present invention to provide a fuel assembly which achieves a high thermal efficiency and a stable lifetime performance by preventing an unnecessary flow of a coolant in an outer circumferential area therein and by causing the coolant to effectively flow toward interiorly disposed fuel pins.
To achieve the above object, the present invention provides a fuel assembly charged in a reactor core of a nuclear reactor using a liquid metal as a coolant. The fuel assembly includes a wrapper tube, grids, liner tubes, and a fixing device. The wrapper tube includes an entrance nozzle for introducing the coolant and an operation handling head, and stores a plurality of fuel pins. The grids are disposed in the wrapper tube to support the fuel pins in the radial direction of the wrapper tube. The liner tubes are inserted in the wrapper tube to fixedly hold the respective grids in the axial direction of the wrapper tube. The fixing device fixes the grids and the liner tubes in the radial direction of the wrapper tube.
Further, in a preferable embodiment of the fuel assembly, the fixing device may include pins for fixing joining ends of the grids and the liner tubes along the radial direction of the wrapper tube.
Furthermore, the fixing device may further include pin support portions, which are through holes formed on an outer circumferential side of a grid frame of each of the grids at positions corresponding to positions of engaging portions of the liner tubes, and through which the pins can be inserted in the vertical direction.
The fuel assembly may further include a coolant blocking member for preventing the coolant from flowing in a gap between the inner circumference of the wrapper tube and the outer circumference of each of the liner tubes. The coolant blocking member may include contact pieces, which project from an outer circumferential side of the liner tube to come in contact with the inner surface of the wrapper tube, and which are formed of an elastic material capable of increasing the range of closure in accordance with the expansion of the wrapper tube.
The coolant blocking member may be a skirt-shaped member hanging from an upper end portion of the liner tube along the outer circumferential surface of the liner tube, and may include a plurality of divided pieces divided by vertically extending grooves to individually come in contact with the inner circumferential surface of the wrapper tube. It is preferable to form the coolant blocking member from a high nickel steel.
Further, the inner circumferential surface of a grid frame of each of the grids may be formed with a plurality of projections for closing gaps between outer peripherally disposed ones of the fuel pins. The projections may be formed in accordance with the pin pitch of the fuel pins.
Furthermore, the fuel assembly may have a structure in which at least either one of a grid frame of each of the grids and a peripheral wall of each of the liner tubes is formed as a concave and convex wall bent toward the inner circumference thereof, and in which parts of the concave and convex wall projecting toward the inner circumference thereof close gaps between outer peripherally disposed ones of the fuel pins. An end portion of either one of the grid frame and the liner tube may be provided with closure portions for closing a space on the outer circumferential side of the parts of the concave and convex wall closing the gaps between the outer peripherally disposed ones of the fuel pins.
The inner circumferential surface of each of the liner tubes may be provided with a plurality of rod members extending along the axial direction. Each of the rod members may have a substantially angular cross section and be disposed in accordance with the pin pitch of the fuel pins to close gaps between outer peripherally disposed ones of the fuel pins.
Further, an upper end portion in the wrapper tube may be provided with an upper pin support plate for supporting the fuel pins, and the upper pin support plate may be pierced through by a tie rod, the upper end of which presses and holds downward the grids and the liner tubes via an elastic member. It is preferable to form the elastic member by a compression coil spring.
Furthermore, a peripheral wall of each of the liner tubes may be drilled with a plurality of holes piercing through the peripheral wall to allow the coolant to flow between a space on the side of the wrapper tube and a space on the side of the fuel pins.
According to the present invention, with the provision of the fixing device for fixing the end portions of the grids and the liner tubes in the radial direction, a gap can be prevented from being formed between the grids and the liner tubes by a positional misalignment in the radial direction. Therefore, the unnecessary flow of the coolant can be prevented, and the improvement of the thermal efficiency of the fuel assembly and the stabilization of the lifetime performance of the fuel assembly can be achieved.
Further characteristics of the present invention will be made clearer from the following detailed description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a schematic overall cross-sectional view illustrating a first embodiment of a fuel assembly according to the present invention;
FIG. 2 is an enlarged cross-sectional view of FIG. 1 taken along the line II-II in FIG. 1 ;
FIG. 3 is a side view of the liner tube illustrated in FIG. 2 ;
FIG. 4 is a side view illustrating a connection structure of the liner tube illustrated in FIG. 3 ;
FIG. 5 is an enlarged cross-sectional view taken along the line V-V in FIG. 1 ;
FIG. 6 is a side view of the liner tube illustrated in FIG. 5 ;
FIG. 7 is a side view illustrating a connection structure of the liner tube illustrated in FIG. 6 ;
FIG. 8 is a schematic view illustrating a second embodiment of the fuel assembly according to the present invention;
FIG. 9 is an enlarged cross-sectional view taken along the line IX-IX in FIG. 8 ;
FIG. 10 is a transverse cross-sectional view of the liner tube illustrated in FIG. 9 ;
FIG. 11 is an explanatory view of a coolant blocking member according to the second embodiment of the present invention;
FIG. 12 is a plan view of the coolant blocking member illustrated in FIG. 11 ;
FIG. 13 is a side view of the coolant blocking member;
FIG. 14 is a cross-sectional view of the coolant blocking member (a cross-sectional view taken along the line XIV-XIV in FIG. 12 );
FIG. 15 is a perspective view of the coolant blocking member;
FIG. 16 is a plan view illustrating the action of the coolant blocking member;
FIG. 17 is a vertical cross-sectional view illustrating the coolant blocking member;
FIG. 18 is a schematic view illustrating a third embodiment of the fuel assembly according to the present invention;
FIG. 19 is a transverse cross-sectional view of FIG. 18 ;
FIG. 20 is a schematic view illustrating a fourth embodiment of the fuel assembly according to the present invention;
FIG. 21 is a partially enlarged cross-sectional view of FIG. 20 ;
FIG. 22 is an enlarged view of main parts of FIG. 21 ;
FIG. 23 is a schematic view illustrating a conventional example;
FIG. 24 is a cross-sectional view taken along the line XXIV-XXIV in FIG. 23 ;
FIG. 25 is a schematic view illustrating a grid of the conventional example;
FIG. 26 is a schematic view illustrating a pin support member of the grid of the conventional example; and
FIG. 27 is a plan view for explaining the expansion of a wrapper tube.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of a fuel assembly according to the present invention will be described below with reference to FIGS. 1 to 22 .
First Embodiment
FIGS. 1 to 7
FIG. 1 is a schematic overall cross-sectional view illustrating a first embodiment of the fuel assembly according to the present invention. FIG. 1 illustrates a state in which only a wrapper tube, described hereinafter, is cut out in a right half of the figure from a center line O and liner tubes included in the wrapper tube are also cut out in a left half of the figure from the center line O.
As illustrated in FIG. 1 , a fuel assembly 1 according to the present embodiment includes a vertically long wrapper tube 2 . The wrapper tube 2 includes an entrance nozzle 3 at a lower end portion thereof and a handling head 4 at an upper end portion thereof. The wrapper tube 2 stores therein a plurality of vertically long fuel pins 5 extending parallel to one another. The fuel pins 5 are supported at upper and lower end portions thereof by an upper pin support plate 6 provided at an upper end position within the wrapper tube 2 and by a lower pin support plate 7 provided at a lower end position within the wrapper tube 2 .
Inside the wrapper tube 2 , a plurality of grids 9 are disposed at intervals in the vertical direction (i.e., the axial direction) suitable for holding the fuel pins 5 at regular intervals in the radial direction. Further, liner tubes 8 are provided inside the wrapper tube 2 so as to be in contact with the respective grids 9 to support the grids 9 in the axial direction. That is, the grids 9 and the liner tubes 8 are disposed to be alternately adjacent to each other along the axial direction of the wrapper tube 2 .
FIG. 2 is an enlarged cross-sectional view (i.e., a transverse cross-sectional view) of FIG. 1 taken along the line II-II line in FIG. 1 , which illustrates two liner tubes 8 ( 8 a ) disposed on the upper end side of the wrapper tube 2 and the internal structure of the liner tubes. Further, FIG. 3 illustrates a lateral shape of the liner tube 8 ( 8 a ) illustrated in FIG. 2 (the wrapper tube 2 is omitted).
As illustrated in FIGS. 1 to 3 , the wrapper tube 2 and the liner tube 8 ( 8 a ) both have a cross-section of a regular hexagonal shape. Each of the two liner tubes 8 ( 8 a ) disposed on the upper side of the fuel assembly 1 , for example, is drilled with communication holes 14 penetrating the tube wall of the liner tube. The communication holes 14 communicate the space inside the liner tube 8 ( 8 a ) with the space between the wrapper tube 2 and the liner tube 8 ( 8 a ). In a nuclear reactor operation, therefore, a coolant can freely flow between the space inside the liner tube 8 ( 8 a ) and the space formed between the wrapper tube 2 and the liner tube 8 ( 8 a ). As the coolant flows from a high fluid pressure side to a low fluid pressure side, the liquid pressure is constantly kept uniform between the two spaces in the operation.
In the example illustrated in FIGS. 1 to 3 , the communication holes 14 are formed at two positions in the vertical direction in one of the surfaces of each of the liner tubes 8 ( 8 a ). However, the disposition, the number, and the like of the communication holes 14 are not particularly limited.
Further, as illustrated in FIGS. 2 and 3 , engaging portions 10 formed by grooves, holes, or the like are provided to open upward and toward the outer circumferential side, for example, at respective positions in the vicinity of the upper end corners of the respective surfaces forming each of the liner tubes 8 ( 8 a ). The engaging portions 10 formed by grooves, holes, or the like are also provided to open downward and toward the outer circumferential side, for example, at respective positions in the vicinity of the lower end corners of the respective surfaces forming each of the liner tubes 8 ( 8 a ). Furthermore, as illustrated in FIG. 3 , a latch pin 11 of a predetermined length is provided for each of the engaging portions 10 so that end portions of the latch pin 11 can be inserted in the corresponding engaging portions 10 formed by grooves or the like.
FIG. 4 illustrates a state in which a pair of upper and lower liner tubes 8 ( 8 a ) and a grid 9 disposed therebetween are connected together with the engaging portions 10 and the latch pins 11 . The grid 9 is formed by a grid frame of a regular hexagonal shape and a plurality of fuel pin support rings provided inside the grid frame (see FIGS. 25 and 26 , for example). As illustrated in FIG. 4 , pin support portions 15 are provided on an outer circumferential side of the grid frame of the grid 9 in an arrangement corresponding to the arrangement of the engaging portions 10 of the liner tubes 8 ( 8 a ). Each of the pin support portions 15 is formed as a through hole or the like formed on the outer circumferential side of the grid frame, for example, and is configured to be inserted with the vertically set latch pin 11 in the vertical direction and to support a central portion of the latch pin 11 from the outer circumferential side.
In the above-described configuration, the grid 9 is disposed between the pair of the upper and lower liner tubes 8 ( 8 a ), and the central portions of the latch pins 11 are supported by the pin support portions 15 of the grid 9 . Further, the upper and lower end portions of the latch pins 11 are inserted in the engaging portions 10 of the upper and lower liner tubes 8 ( 8 a ), which are formed by grooves or the like. Therefore, the upper and lower liner tubes 8 ( 8 a ) and the grid 9 can be vertically connected together, with the outer circumferential surfaces of the three components being aligned to one another. According to such configuration, the vertically adjacent liner tubes 8 ( 8 a ) and the grid 9 are fixed to one another in the radial direction. That is, a gap is prevented from being formed between the liner tubes 8 ( 8 a ) and the grid 9 by a positional misalignment in the radial direction. Accordingly, it is possible to prevent an unnecessary flow of the coolant and to thereby improve the thermal efficiency of the fuel assembly and stabilize the lifetime performance of the fuel assembly.
Description will now be made of the configuration of a lower part of the fuel assembly 1 according to the present embodiment. FIG. 5 is an enlarged cross-sectional view taken along the line V-V in FIG. 1 , which illustrates the configuration of liner tubes 8 ( 8 b ) of the fuel assembly 1 disposed below the two upper liner tubes 8 ( 8 a ), for example. FIG. 6 is a side view of the liner tube 8 ( 8 b ) illustrated in FIG. 5 .
The liner tube 8 ( 8 b ) illustrated in FIGS. 5 and 6 is in the shape of a cylinder, the basic form of which is a regular hexagon. The liner tube 8 ( 8 b ) is configured such that the peripheral wall corresponding to the respective sides of the liner tube 8 ( 8 b ) is partially bent toward the inner circumference thereof to form angular concavities and convexities that fill gaps between peripherally disposed ones of the fuel pins 5 . With such concavities and convexities, angular portions (i.e., triangular convexities) 16 are formed as peripheral flow preventing projections projecting toward the inner surface of the liner tube 8 ( 8 b ). Accordingly, the gaps between the peripherally disposed ones of the fuel pins 5 can be closed. Further, a peripheral flow preventing structure is formed which prevents the coolant from passing through the space between the fuel pins 5 and the inner circumference of the liner tube 8 ( 8 b ) and flowing upward.
Similarly, as illustrated in FIG. 7 , the peripheral wall corresponding to the respective sides of the grid frame of the grid 9 , having the regular hexagonal basic form, is partially bent toward the inner circumference thereof. Thus, the grid frame has angular portions that fill the gaps between the peripherally disposed ones of the fuel pins 5 .
In the above-described configuration, each of the liner tubes 8 ( 8 b ) is drilled with the communication holes 14 penetrating the tube wall of the liner tube. The communication holes 14 communicate the space inside the liner tube 8 ( 8 b ) with the space between the wrapper tube 2 and the liner tube 8 ( 8 b ). In the nuclear reactor operation, therefore, the coolant can freely flow between the space inside the liner tube 8 ( 8 b ) and the space formed between the wrapper tube 2 and the liner tube 8 ( 8 b ). As the coolant flows from a high fluid pressure side to a low fluid pressure side, the liquid pressure is constantly kept uniform between the two spaces in the operation. In the example illustrated in FIGS. 5 to 7 , the communication holes 14 are formed at two positions in the vertical direction in one of the surfaces of each of the liner tubes 8 ( 8 b ). However, the arrangement, the number, and the like of the communication holes 14 are not particularly limited.
As described above, each of the sides of the liner tube 8 ( 8 b ) has the cross section having the concavities and convexities. Parts of the outer circumferential surface of the side corresponding to the angular portions 16 form the concavities. In the present configuration, therefore, there is no need to provide the engaging portions 10 illustrated in FIGS. 3 and 4 , and the concavities of the angular portions 16 can be used as the engaging portions engaged with the latch pins 11 .
FIG. 7 illustrates a state in which a pair of upper and lower liner tubes 8 ( 8 b ) and a grid 9 disposed therebetween are connected together with the angular portions 16 , which serve as the engaging portions, and the latch pins 11 . Similarly to each of the liner tubes 8 ( 8 b ), the grid 9 is configured to have an outer circumferential surface having concavities formed by angular portions. Therefore, substantially similarly to FIG. 4 , the pin support portions 15 are provided in an arrangement corresponding to that of the concavities of the liner tubes 8 ( 8 b ). In this way, each of the lower liner tubes 8 ( 8 b ) and grids 9 of the present embodiment can be attached with the latch pins 11 on the outer circumference thereof, with no need of being formed with the grooves or the like.
Accordingly, the upper and lower liner tubes 8 ( 8 b ) and the grid 9 can be vertically connected together, with the outer circumferential surfaces of the three components being aligned to one another, by disposing the grid 9 between the pair of the upper and lower liner tubes 8 ( 8 b ), causing the pin support portions 15 of the grid 9 to support the central portions of the latch pins 11 , and inserting the upper and lower end portions of the latch pins 11 in the concavities of the outer circumferential surfaces of the upper and lower liner tubes 8 ( 8 b ), which are formed by the angular portions 16 .
With this configuration, the vertically adjacent liner tubes 8 ( 8 b ) and the grid 9 can be fixed to one another in the radial direction. Thus, with a relatively small number of processes, a gap is prevented from being formed between the liner tubes 8 ( 8 b ) and the grid 9 by a positional misalignment in the radial direction. Accordingly, it is possible to prevent the unnecessary flow of the coolant, and thus, to improve the thermal efficiency of the fuel assembly and stabilize the lifetime performance of the fuel assembly, for example.
It is preferable to set the thickness of the liner tube so as to prevent a gap from being formed in a joining area of the grid and the liner tube, even if a lateral misalignment is caused by the amount of a gap between the wrapper tube and the liner tube.
Second Embodiment
FIGS. 8 to 17
In a second embodiment of the present invention, description will be made of a fuel assembly including a coolant blocking member 17 for preventing the coolant from flowing in a gap between the inner circumference of the wrapper tube 2 and the outer circumference of the liner tube 8 ( 8 b ).
FIG. 8 is a schematic overall cross-sectional view illustrating the second embodiment of the fuel assembly according to the present invention. FIG. 8 illustrates a state in which only a wrapper tube is cut out in a right half of the figure from a center line O and liner tubes included in the wrapper tube are also cut out in a left half of the figure from the center line O.
As illustrated in FIG. 8 , a fuel assembly 1 according to the present embodiment includes a vertically long wrapper tube 2 . The wrapper tube 2 has an entrance nozzle 3 at a lower end portion thereof and a handling head 4 at an upper end portion thereof. The wrapper tube 2 stores therein a plurality of vertically long fuel pins 5 extending parallel to one another. The fuel pins 5 are supported at upper and lower end portions thereof by an upper pin support plate 6 provided at an upper end position within the wrapper tube 2 and by a lower pin support plate 7 provided at a lower end position within the wrapper tube 2 .
Inside the wrapper tube 2 , a plurality of grids 9 are disposed at intervals in the vertical direction (i.e., the axial direction) to hold the fuel pins 5 at regular intervals in the radial direction. Further, liner tubes 8 are provided inside with the wrapper tube 2 to be in contact with the respective grids 9 to support the grids 9 in the axial direction. That is, the grids 9 and the liner tubes 8 are disposed to be alternately adjacent to each other along the axial direction of the wrapper tube 2 .
The present embodiment is similar to the above-described first embodiment in two liner tubes 8 ( 8 a ) disposed on the upper end side of the wrapper tube 2 and in the internal structure of the liner tubes. Therefore, description of the liner tubes 8 ( 8 a ) and the internal structure thereof will be omitted.
In the present embodiment, description will be mainly made of the configuration of liner tubes 8 ( 8 b ) disposed below the two upper liner tubes 8 ( 8 a ). FIG. 9 is an enlarged cross-sectional view of FIG. 8 taken along the IX-IX line, and FIG. 10 is a transverse cross-sectional view extracting and illustrating only the liner tube 8 ( 8 b ) illustrated in FIG. 9 .
As illustrated in the above figures, in the present embodiment, the liner tube 8 ( 8 b ) is in the shape of a cylinder, the basic form of which is a regular hexagon. The liner tube 8 ( 8 b ) is configured such that the peripheral wall corresponding to the respective sides of the liner tube 8 ( 8 b ) is bent toward the inner circumference thereof to form angular concavities and convexities that fill gaps between peripherally disposed ones of the fuel pins 5 . With such concavities and convexities, angular portions (i.e., triangular convexities) 16 are formed as peripheral flow preventing projections projecting toward the inner surface of the liner tube 8 ( 8 b ). Accordingly, the gaps between the peripherally disposed ones of the fuel pins 5 can be closed. Further, a peripheral flow preventing structure is formed which prevents the coolant from passing through the space between the fuel pins 5 and the inner circumference of the liner tube 8 ( 8 b ) and flowing upward.
That is, as illustrated in FIG. 10 , the present embodiment has a structure in which the peripheral wall of the liner tube 8 ( 8 b ) is formed as a concave and convex wall bent toward the inner circumference thereof, and in which the gaps between the outer peripherally disposed ones of the fuel pins 5 are closed by parts of the concave and convex wall projecting toward the inner circumference thereof. Further, an end portion of the liner tube 8 ( 8 b ) is provided with closure portions 19 for closing the space on the outer circumferential side of the parts of the concave and convex wall closing the gaps between the outer peripherally disposed ones of the fuel pins 5 .
Although not illustrated, the inner circumferential surface of a grid frame of the grid 9 may be also provided with a plurality of projections for closing the gaps between the outer peripherally disposed ones of the fuel pins 5 , and the projections may be formed in accordance with the pin pitch of the fuel pins 5 .
That is, the present embodiment has a structure in which at least one of the grid frame of the grid 9 and the peripheral wall of the liner tube 8 ( 8 b ) is formed as the concave and convex wall bent toward the inner circumference thereof, and in which the parts of the concave and convex wall projecting toward the inner circumference thereof close the gaps between the outer peripherally disposed ones of the fuel pins 5 .
With reference to FIGS. 11 to 17 , description will be then made of the liner tube 8 ( 8 b ) provided with the coolant blocking member 17 for preventing the coolant from flowing in the gap between the inner circumference of the wrapper tube 2 and the outer circumference of the liner tube 8 ( 8 b ).
As illustrated in FIG. 11 , the coolant blocking member 17 includes contact pieces 18 a , 18 b , and 18 c , which are positioned on an upper end side of the liner tube 8 ( 8 b ) and formed of an elastic material capable of increasing the range of closure in accordance with the expansion of the wrapper tube 2 caused by the irradiation. Specifically, as illustrated in FIG. 17 , the coolant blocking member 17 includes the contact pieces 18 a , 18 b , and 18 c , which project from the outer circumferential side of the liner tube 8 ( 8 b ) to come in contact with the inner surface of the wrapper tube 2 .
Further, the coolant blocking member 17 is a skirt-shaped member hanging from the upper end portion of the liner tube 8 ( 8 b ) along the outer circumferential surface of the liner tube, and is configured to include the contact pieces 18 a , 18 b , and 18 c , which are a plurality of divided pieces divided by vertically extending grooves 18 to individually come in contact with the inner circumferential surface of the wrapper tube 2 . It is preferable to form the coolant blocking member 17 from a high nickel steel such as Inconel (Trade Name), for example. Thus formed, the coolant blocking member 17 can keep the spring force thereof for a long time.
FIG. 12 is a plan view illustrating the configuration of the coolant blocking member 17 illustrated in FIG. 11 , and FIG. 13 is a side view similarly illustrating the configuration of the coolant blocking member 17 . FIG. 14 is a cross-sectional view (a cross-sectional view of FIG. 12 taken along the line XIV-XIV) illustrating the specific configuration of the coolant blocking member 17 , and FIG. 15 is a perspective view of the coolant blocking member 17 . FIG. 16 is a plan view illustrating the action of the coolant blocking member 17 , and FIG. 17 is a vertical cross-sectional view of the coolant blocking member 17 . In FIG. 16 , if the wrapper tube 2 is expanded from a state indicated by a virtual line into a state indicated by a solid line due to the thermal expansion occurring in the operation, the contact piece 18 a positioned at the center of each of the sides of the coolant blocking member 17 follows the expanded wrapper tube 2 and moves toward a central portion of the corresponding one of the sides of the wrapper tube 2 , which is the most expanded portion of the wrapper tube 2 . Thereby, the contact piece 18 a comes in contact with the inner surface of the wrapper tube 2 , and the space on the inner circumferential side of the wrapper tube 2 can be closed. Further, as illustrated in FIG. 12 , an upper end portion of the liner tube 8 ( 8 b ) is provided with the closure portions 19 for closing the space on the outer circumferential side of the parts of the concave and convex wall closing the gaps between the peripherally disposed ones of the fuel pins 5 .
As illustrated in FIGS. 15 and 17 , the skirt-shaped coolant blocking member 17 is divided into an upper portion 17 a not formed with the grooves 18 , an intermediate portion 17 b formed with the grooves 18 and flared in a skirt shape, and a lower end portion 17 c gradually bent inward toward the lower side. An uppermost portion 17 d serves as a connection portion connected to the liner tube 8 ( 8 b ).
Although not illustrated, the present embodiment may be configured such that an end portion of either one of the grid frame of the grid 9 and the liner tube 8 ( 8 b ) is provided with the closure portions for closing the space on the outer circumferential side of the parts of the convex and concave wall closing the gaps between the peripherally disposed ones of the fuel pins 5 .
As described above, the present embodiment is configured such that the coolant blocking member 17 is provided on the outer circumferential surface side of the liner tube 8 ( 8 b ) for preventing the coolant from flowing in the gap between the outer circumferential surface of the liner tube 8 ( 8 b ) and the inner circumferential surface of the wrapper tube 2 , and that the coolant blocking member 17 includes the contact pieces 18 a , 18 b , and 18 c formed of an elastic material capable of increasing the range of closure in accordance with the expansion of the gap caused by the expansion of the wrapper tube 2 due to the irradiation expansion. The present embodiment is further configured such that the coolant blocking member 17 is formed as a ring-shaped spring plate, which is disposed on the outer circumferential surface side of the liner tube 8 ( 8 b ) along the circumferential direction, and which includes the contact pieces 18 a , 18 b , and 18 c formed by a plurality of divided pieces divided by the vertically formed grooves 18 to individually come in contact with the inner circumferential surface of the wrapper tube 2 .
According to the present embodiment, therefore, even if a flow passage is opened in the gap between the wrapper tube 2 and the liner tube 8 , an unnecessary flow of the coolant can be prevented by the coolant blocking member 17 . Further, the present embodiment has a configuration similar to the configuration of the first embodiment. Thus, the liner tubes 8 and the grids 9 are alternately stacked to determine the positions of the grids 9 , and the mutual relative positions of the liner tubes 8 and the grids 9 are fixed by using the latch pins 11 between the liner tubes 8 and the grids 9 . A misalignment in the radial direction can be thereby prevented. Furthermore, the communication holes 14 are formed to communicate the internal pressure of the liner tubes 8 with the internal pressure of the wrapper tube 2 . Accordingly, the deformation of the liner tubes 8 can be prevented.
Further, the so-called gap flow preventing plate is provided in the gap between the wrapper tube 2 and the liner tubes 8 to prevent the coolant from flowing in the gap even if the liner tubes 8 and the grids 9 are misaligned. The deformation is greater in a near-center portion than in a corner portion of each of the surfaces of the wrapper tube 2 . Since the above gap flow preventing plate has a structure of a spring divided in the circumferential direction, the gap flow preventing plate can reliably close the flow passage even if there is such a difference in expansion.
Third Embodiment
FIGS. 18 and 19
FIG. 18 is a partial cross-sectional view illustrating a third embodiment of the present invention, and FIG. 19 is a transverse cross-sectional view of FIG. 18 .
As illustrated in the above figures, in the present embodiment, the inner circumferential surface of the liner tube 8 is provided with a plurality of rods 20 extending along the axial direction. Each of the rods 20 has a substantially angular cross section and is disposed in accordance with the pin pitch of fuel pins 5 . Further, the rods 20 are configured to close the gaps between the outer peripherally disposed ones of the fuel pins 5 . That is, the inner circumferential surface of the liner tube 8 is provided with the plurality of the rods 20 , each of which has the substantially angular cross section, and which are disposed in accordance with the pin pitch of the fuel pins 5 along the axial direction to close the gap between the inner circumferential surface of the liner tube 8 and the fuel pins 5 .
According to the present embodiment, a peripheral flow can be prevented by providing the peripheral flow preventing rods 20 , each of which has a triangular cross section, instead of forming the peripheral flow preventing structure.
Fourth Embodiment
FIGS. 20 to 22
FIG. 20 is a schematic view illustrating a fourth embodiment of the present invention, and FIG. 21 is a partially enlarged cross-sectional view of FIG. 20 . Further, FIG. 22 is an enlarged view of main parts of FIG. 21 .
The present embodiment is configured such that an upper end portion in the wrapper tube 2 is provided with the upper pin support plate 6 for supporting the fuel pins 5 , and that a tie rod 21 penetrating the upper pin support plate 6 has an upper end which can be pressed down by an upper end plug 25 via an elastic member 24 such as a compression coil spring. The grids 9 and the liner tubes 8 are pressed and held downward by the elastic member 24 .
That is, an upper pin support ring 23 is provided at an upper end position in the wrapper tube 2 , and the upper end of the tie rod 21 penetrating the upper pin support ring 23 is pressed down by the upper end plug 25 via the elastic member 24 such as a compression coil spring. Thus, the grids 9 and the liner tubes 8 are pressed and held downward by the elastic member 24 with the elastic force.
According to the above-described configuration, the entirety of the components can be held by causing the upper end plug 25 of the tie rod 21 (the fuel pin 5 ) to press the uppermost grid 9 via the elastic member 24 in a manner such that the liner tubes 8 and the grids 9 will not be misaligned. Accordingly, even if the expansion occurs due to the heat of the fuel and the irradiation, the entirety of the components can be reliably held by causing the fuel pin 5 itself to pull the entirety of the components. At the same time, the other fuel pins 5 are allowed to freely expand.
It is preferable to provide a ring having the same shape as the shape of the outer diameter of the ring element to properly apply the elastic force of the elastic member 24 to the grid 9 to thereby reliably apply the pressing force to the grid 9 .
With the liner tubes 8 and the grids 9 thus held with the elastic member 24 by the upper end plug 25 of one of the fuel pins 5 , the fuel pins 5 , the grids 9 , and the liner tubes 8 can be integrally handled, and the free expansion of the other fuel pins 5 is not interrupted.
The present invention is not limited to the embodiments described above, and other alterations and modifications may be made in the present invention as long as not departing from the scope of the appended claims. | 4y
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RELATED APPLICATIONS
[0001] This patent application is a continuation application of U.S. patent application Ser. No. 15/613,061, filed Jun. 2, 2017, which is a divisional application of U.S. patent application Ser. No. 13/842,044, filed Mar. 15, 2013, which claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/735,895, filed Dec. 11, 2012. U.S. patent application Ser. Nos. 13/842,044 and 15/613,061 are herein incorporated by reference.
TECHNICAL FIELD
[0002] Some embodiments of the present invention relate, in general, to a substrate support assembly such as an electrostatic chuck that has a plasma resistant protective layer. Other embodiments relate to reactive multi-layer foils and the manufacture of reactive multi-layer foils.
BACKGROUND
[0003] In the semiconductor industry, devices are fabricated by a number of manufacturing processes producing structures of an ever-decreasing size. Some manufacturing processes such as plasma etch and plasma clean processes expose a substrate support (e.g., an edge of the substrate support during wafer processing and the full substrate support during chamber cleaning) to a high-speed stream of plasma to etch or clean the substrate. The plasma may be highly corrosive, and may corrode processing chambers and other surfaces that are exposed to the plasma.
[0004] Additionally, traditional electrostatic chucks include a ceramic puck silicone bonded to a metal cooling plate. The Ceramic puck in such traditional electrostatic chucks is manufactured by a multi-step manufacturing process that can be costly to form an embedded electrode and heating elements.
[0005] Reactive multilayer foils (referred to herein as reactive foils) are used to form a metal bond between substrates. Traditional reactive foil is manufactured in flat featureless sheets. Traditional reactive foil is typically not appropriate for bonding substrates having non-flat surfaces. Additionally, if the traditional reactive foil is used to bond substrates having surface features, the reactive foil is machined (e.g., by laser drilling, chemical etching, etc.) to form corresponding features in the reactive foil. Such machining can induce a heat load on the reactive foil and cause the reactive foil to ignite. Moreover, traditional reactive foil has a preset size such as 9 inch squares. When the traditional reactive foil is used to bond substrates that are larger than the reactive foil, then multiple sheets of reactive foil are used to perform the bonding. This commonly introduces leakage paths such as cracks, grooves, lines, etc. between the reactive foil sheets, and causes the resultant metal bond to not be vacuum sealed.
SUMMARY
[0006] In one embodiment, an electrostatic chuck includes a ceramic body and a thermally conductive base bonded to a lower surface of the ceramic body. The ceramic body may be bonded to the thermally conductive base by a metal bond or by a silicone bond. The electrostatic chuck is fabricated with a protective layer bonded to an upper surface of the ceramic body by a metal bond, the protective layer comprising a bulk sintered ceramic article.
[0007] In another embodiment, reactive foil is manufactured. A template having one or more surface features is provided. Alternating nanoscale layers of aluminum and nickel are deposited onto the template to form a reactive foil sheet. The reactive foil sheet is removed from the template. The resultant reactive foil sheet has one or more foil features corresponding to one or more surface features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that different references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
[0009] FIG. 1 depicts a sectional view of one embodiment of a processing chamber;
[0010] FIG. 2 depicts an exploded view of one embodiment of a substrate support assembly;
[0011] FIG. 3 depicts a side view of one embodiment of a substrate support assembly;
[0012] FIG. 4 depicts an exploded side view of one embodiment of a substrate support;
[0013] FIG. 5 illustrates one embodiment of a process for manufacturing an electrostatic chuck;
[0014] FIG. 6 illustrates another embodiment of a process for manufacturing an electrostatic chuck; and
[0015] FIG. 7 illustrates one embodiment of a process for performing a metal bonding process.
[0016] FIG. 8 illustrates one embodiment of a process for manufacturing reactive foil having preformed foil features.
[0017] FIG. 9A illustrates deposition of nanoscale metal layers onto a template having surface features.
[0018] FIG. 9B illustrates a reactive foil sheet having preformed foil features.
[0019] FIG. 10A illustrates deposition of nanoscale metal layers onto a non-planar template.
[0020] FIG. 10B illustrates a non-planar reactive foil sheet.
[0021] FIG. 11 illustrates interlocking reactive foil sheets.
DETAILED DESCRIPTION OF EMBODIMENTS
[0022] Embodiments of the present invention provide a substrate support assembly (e.g., an electrostatic chuck) having a protective layer formed over a ceramic body of the substrate support assembly. The protective layer may provide plasma corrosion resistance for protection of the ceramic body. The protective layer may be a bulk sintered ceramic article (e.g., a ceramic wafer) that is metal bonded to the ceramic body using a nano-bonding technique. Various bonding materials such as In, Sn, Ag, Au, Cu and their alloys could be used along with a reactive foil.
[0023] In one embodiment, the ceramic body is a bulk sintered ceramic body (e.g., another ceramic wafer). When the ceramic body does not include a chucking electrode, the metal bond may function as a chucking electrode for the electrostatic chuck. The ceramic body may additionally be metal bonded to a thermally conductive base by another metal bond. The thermally conductive base may include heating elements as well as channels that can be used to regulate temperature by flowing liquid for heating and/or cooling. The metal bond between the thermally conductive base and the ceramic body provides a good thermal contact, and enables the thermally conductive base to heat and cool the ceramic body, the protective layer and any substrate held by the electrostatic chuck during processing. Embodiments provide an electrostatic chuck that can be as much as 4 x cheaper to manufacture than conventional electrostatic chucks. Moreover, embodiments provide an electrostatic chuck that can adjust temperature rapidly and that is plasma resistant. The electrostatic chuck and a substrate being supported may be heated or cooled quickly, with some embodiments enabling temperature changes of 2° C./s or faster. This enables the electrostatic chuck to be used in multi-step processes in which, for example, a wafer may be processed at 20-30° C. and then rapidly ramped up to 80-90° C. for further processing. The embodiments described herein may be used for both Columbic electrostatic chucking applications and Johnson Raybek chucking applications.
[0024] In another embodiment, reactive foil is manufactured that has preformed surface features. The reactive foil may be manufactured by depositing alternating nanoscale layers of two reactive materials such as aluminum and nickel onto a template that has surface features. The surface features of the template may correspond to surface features of one or more substrates that the reactive foil will be used to bond. For example, if the one or more substrates have holes in them, then the template may have steps corresponding to the holes. These steps may cause reactive foil formed on the template to have preformed holes that correspond to the holes in the substrate.
[0025] FIG. 1 is a sectional view of one embodiment of a semiconductor processing chamber 100 having a substrate support assembly 148 disposed therein. The substrate support assembly 148 has a protective layer 136 of a bulk ceramic that has been metal bonded to a ceramic body of the substrate support assembly 148 . The metal bond may include a combination of metals, such as a combination of indium, tin, aluminum, nickel and one or more additional metals (e.g., such as gold or silver). The metal bonding process is described in greater detail below.
[0026] The protective layer may be a bulk ceramic (e.g., a ceramic wafer) such as Y 2 O 3 (yttria or yttrium oxide), Y 4 Al 2 O 9 (YAM), Al 2 O 3 (alumina) Y 3 Al 5 O 12 (YAG), YAlO3 (YAP), Quartz, SiC (silicon carbide) Si 3 N 4 (silicon nitride) Sialon, Minn. (aluminum nitride), AlON (aluminum oxynitride), TiO 2 (titania), ZrO 2 (zirconia), TiC (titanium carbide), ZrC (zirconium carbide), TiN (titanium nitride), TiCN (titanium carbon nitride) Y 2 O 3 stabilized ZrO 2 (YSZ), and so on. The protective layer may also be a ceramic composite such as Y 3 Al 5 O 12 distributed in Al 2 O 3 matrix, Y 2 O 3 —ZrO 2 solid solution or a SiC—Si 3 N 4 solid solution. The protective layer may also be a ceramic composite that includes a yttrium oxide (also known as yttria and Y 2 O 3 ) containing solid solution. For example, the protective layer may be a ceramic composite that is composed of a compound Y 4 Al 2 O 9 (YAM) and a solid solution Y 2 -xZr x O 3 (Y 2 O 3 —ZrO 2 solid solution). Note that pure yttrium oxide as well as yttrium oxide containing solid solutions may be doped with one or more of ZrO 2 , Al 2 O 3 , SiO 2 , B 2 O 3 , Er 2 O 3 , Nd 2 O 3 , Nb 2 O 5 , CeO 2 , Sm 2 O 3 , Yb 2 O 3 , or other oxides. Also note that pure Aluminum Nitride as well as doped Aluminum Nitride with one or more of ZrO 2 , Al 2 O 3 , SiO 2 , B 2 O 3 , Er 2 O 3 , Nd 2 O 3 , Nb 2 O 5 , CeO 2 , Sm 2 O 3 , Yb 2 O 3 , or other oxides may be used. Alternatively, the protective layer may be sapphire or MgAlON.
[0027] The protective layer may be a sintered ceramic article that was produced from a ceramic powder or a mixture of ceramic powders. For example, the ceramic composite may be produced from a mixture of a Y 2 O 3 powder, a ZrO 2 powder and an Al 2 O 3 powder. The ceramic composite may include Y 2 O 3 in a range of 50-75 mol %, ZrO 2 in a range of 10-30 mol % and Al 2 O 3 in a range of 10-30 mol %. In one embodiment, the HPM ceramic composite contains approximately 77% Y 2 O 3 , 15% ZrO 2 and 8% Al 2 O 3 . In another embodiment, the ceramic composite contains approximately 63% Y 2 O 3 , 23% ZrO 2 and 14% Al 2 O 3 . In still another embodiment, the HPM ceramic composite contains approximately 55% Y 2 O 3 , 20% ZrO 2 and 25% Al 2 O 3 . Relative percentages may be in molar ratios. For example, the HPM ceramic composite may contain 77 mol % Y 2 O 3 , 15 mol % ZrO 2 and 8 mol % Al 2 O 3 . Other distributions of these ceramic powders may also be used for the ceramic composite.
[0028] The processing chamber 100 includes a chamber body 102 and a lid 104 that enclose an interior volume 106 . The chamber body 102 may be fabricated from aluminum, stainless steel or other suitable material. The chamber body 102 generally includes sidewalls 108 and a bottom 110 . An outer liner 116 may be disposed adjacent the side walls 108 to protect the chamber body 102 . The outer liner 116 may be fabricated and/or coated with a plasma or halogen-containing gas resistant material. In one embodiment, the outer liner 116 is fabricated from aluminum oxide. In another embodiment, the outer liner 116 is fabricated from or coated with yttria, yttrium alloy or an oxide thereof.
[0029] An exhaust port 126 may be defined in the chamber body 102 , and may couple the interior volume 106 to a pump system 128 . The pump system 128 may include one or more pumps and throttle valves utilized to evacuate and regulate the pressure of the interior volume 106 of the processing chamber 100 .
[0030] The lid 104 may be supported on the sidewall 108 of the chamber body 102 . The lid 104 may be opened to allow excess to the interior volume 106 of the processing chamber 100 , and may provide a seal for the processing chamber 100 while closed. A gas panel 158 may be coupled to the processing chamber 100 to provide process and/or cleaning gases to the interior volume 106 through a gas distribution assembly 130 that is part of the lid 104 . Examples of processing gases may be used to process in the processing chamber including halogen-containing gas, such as C 2 F 6 , SF 6 , SiCl 4 , HBr, NF 3 , CF 4 , CHF 3 , CH 2 F 3 , Cl 2 and SiF 4 , among others, and other gases such as O 2 , or N 2 O. Examples of carrier gases include N 2 , He, Ar, and other gases inert to process gases (e.g., non-reactive gases). The gas distribution assembly 130 may have multiple apertures 132 on the downstream surface of the gas distribution assembly 130 to direct the gas flow to the surface of the substrate 144 . Additionally, the gas distribution assembly 130 can have a center hole where gases are fed through a ceramic gas nozzle. The gas distribution assembly 130 may be fabricated and/or coated by a ceramic material, such as silicon carbide, Yttrium oxide, etc. to provide resistance to halogen-containing chemistries to prevent the gas distribution assembly 130 from corrosion.
[0031] The substrate support assembly 148 is disposed in the interior volume 106 of the processing chamber 100 below the gas distribution assembly 130 . The substrate support assembly 148 holds the substrate 144 during processing. An inner liner 118 may be coated on the periphery of the substrate support assembly 148 . The inner liner 118 may be a halogen-containing gas resist material such as those discussed with reference to the outer liner 116 . In one embodiment, the inner liner 118 may be fabricated from the same materials of the outer liner 116 .
[0032] In one embodiment, the substrate support assembly 148 includes a mounting plate 162 supporting a pedestal 152 , and an electrostatic chuck 150 . In one embodiment, the electrostatic chuck 150 further includes a thermally conductive base 164 bonded to an electrostatic puck 166 by a metal or silicone bond 138 . Alternatively, a simple ceramic body may be used instead of the electrostatic puck 166 , as will be described in greater detail with reference to FIG. 3 . An upper surface of the electrostatic puck 166 is covered by the protective layer 136 that is metal bonded to the electrostatic puck 166 . In one embodiment, the protective layer 136 is disposed on the upper surface of the electrostatic puck 166 . In another embodiment, the protective layer 136 is disposed on the entire surface of the electrostatic chuck 150 including the outer and side periphery of the thermally conductive base 164 and the electrostatic puck 166 . The mounting plate 162 is coupled to the bottom 110 of the chamber body 102 and includes passages for routing utilities (e.g., fluids, power lines, sensor leads, etc.) to the thermally conductive base 164 and the electrostatic puck 166 .
[0033] The thermally conductive base 164 and/or electrostatic puck 166 may include one or more optional embedded heating elements 176 , embedded thermal isolators 174 and/or conduits 168 , 170 to control a lateral temperature profile of the support assembly 148 . The conduits 168 , 170 may be fluidly coupled to a fluid source 172 that circulates a temperature regulating fluid through the conduits 168 , 170 . The embedded isolator 174 may be disposed between the conduits 168 , 170 in one embodiment. The heater 176 is regulated by a heater power source 178 . The conduits 168 , 170 and heater 176 may be utilized to control the temperature of the thermally conductive base 164 , thereby heating and/or cooling the electrostatic puck 166 and a substrate (e.g., a wafer) being processed. The temperature of the electrostatic puck 166 and the thermally conductive base 164 may be monitored using a plurality of temperature sensors 190 , 192 , which may be monitored using a controller 195 .
[0034] The electrostatic puck 166 and/or protective layer may further include multiple gas passages such as grooves, mesas and other surface features, that may be formed in an upper surface of the puck 166 and/or the protective layer. The gas passages may be fluidly coupled to a source of a heat transfer (or backside) gas, such as He via holes drilled in the puck 166 . In operation, the backside gas may be provided at controlled pressure into the gas passages to enhance the heat transfer between the electrostatic puck 166 and the substrate 144 .
[0035] In one embodiment, the electrostatic puck 166 includes at least one clamping electrode 180 controlled by a chucking power source 182 . In alternative embodiments, the metal bond may function as the clamping electrode. Alternatively, the protective layer may include an embedded clamping electrode (also referred to as a chucking electrode). The electrode 180 (or other electrode disposed in the puck 166 or protective layer) may further be coupled to one or more RF power sources 184 , 186 through a matching circuit 188 for maintaining a plasma formed from process and/or other gases within the processing chamber 100 . The sources 184 , 186 are generally capable of producing an RF signal having a frequency from about 50 kHz to about 3 GHz and a power of up to about 10,000 Watts. In one embodiment, an RF signal is applied to the metal base, an alternating current (AC) is applied to the heater and a direct current (DC) is applied to the chucking electrode.
[0036] FIG. 2 depicts an exploded view of one embodiment of the substrate support assembly 148 . The substrate support assembly 148 depicts an exploded view of the electrostatic chuck 150 and the pedestal 152 . The electrostatic chuck 150 includes the electrostatic puck 166 or other ceramic body, as well as the thermally conductive base 164 attached to the electrostatic puck 166 or ceramic body. The electrostatic puck 166 or other ceramic body has a disc-like shape having an annular periphery 222 that may substantially match the shape and size of the substrate 144 positioned thereon. In one embodiment, the electrostatic puck 166 or other ceramic body may be fabricated by a ceramic material. Suitable examples of the ceramic materials include aluminum oxide (Al 2 O 3 ), aluminum nitride (AlN), titanium oxide (TiO), titanium nitride (TiN), silicon carbide (SiC) and the like. In one embodiment, the ceramic body is a bulk sintered ceramic, which may be in the form of a wafer.
[0037] The thermally conductive base 164 attached below the electrostatic puck 166 or ceramic body may have a disc-like main portion 224 and an annular flange 220 extending outwardly from a main portion 224 and positioned on the pedestal 152 . In one embodiment, the thermally conductive base 164 may be fabricated by a metal, such as aluminum or stainless steel or other suitable materials. Alternatively, the thermally conductive base 164 may be fabricated by a composite of ceramic, such as an aluminum-silicon alloy infiltrated SiC or Molybdenum to match a thermal expansion coefficient of the ceramic body. The thermally conductive base 164 should provide good strength and durability as well as heat transfer properties. An upper surface of the protective layer 136 may have an outer ring 216 , multiple mesas 210 and channels 208 , 212 between the mesas.
[0038] FIG. 3 illustrates a cross sectional side view of the electrostatic chuck 150 . Referring to FIG. 3 , the thermally conductive base 164 is coupled to a ceramic body 302 by a first metal bond 304 . The ceramic body 302 may be a bulk sintered ceramic such as aluminum oxide (Al 2 O 3 ), aluminum nitride (AlN), titanium oxide (TiO), titanium nitride (TiN), silicon carbide (SiC) and the like. The ceramic body 302 may be provided, for example, as a thin ceramic wafer. In one embodiment, the ceramic body has a thickness of about 1 mm. The ceramic body 302 may have an electrode connection 306 formed therein (e.g., by drilling a hole through the ceramic body and filling the hole with an electrically conductive material. The electrode connection 306 may connect a metal bond that functions as a clamping electrode to a chucking power source and/or to an RF source.
[0039] The first metal bond 304 facilitates thermal energy exchange between the ceramic body 302 and the thermally conductive base 164 and may reduce thermal expansion mismatch therebetween. The metal base 164 may include multiple conduits (e.g., an inner conduit 168 and an outer conduit 170 ) through which fluids may be flowed to heat or cool the electrostatic chuck 150 and a substrate 144 . The metal base 164 may additionally include one or more embedded heaters 176 , which may be resistive heating elements.
[0040] The first metal bond 304 mechanically bonds the thermally conductive base 164 to the ceramic body 302 . In one embodiment, the metal bonding material 304 includes tin and/or indium. Alternatively, other metals may be used. Additionally, the first metal bond 304 may include a thin layer of aluminum and nickel (e.g., having a thickness of about 2-4 mil in one embodiment) between two layers of other metals (e.g., between two layers of tin). In one embodiment, the thin layer is initially a reactive multi-layer foil (referred to herein as a reactive foil) composed of alternating nanoscale layers of reactive materials such as aluminum and nickel. During a room temperature metal bonding process, the reactive foil may be activated (e.g., ignited), creating a near instantaneous reaction generating upwards of 1500 degrees C. This may cause upper and lower layers of metal, which act as a solder, to melt and reflow to bond the thermally conductive base 164 to the ceramic body 302 . In one embodiment, the reactive foil is NanoFoil®, manufactured by Indium Corporation of America.
[0041] The electrostatic chuck 150 additionally includes a protective layer 136 that is coupled to the ceramic body 302 by a second metal bond 308 . The protective layer 136 may be provided, for example, as a thin ceramic wafer. Mesas (not shown) may be formed on a surface of the protective layer, and the protective layer and ceramic body may include holes for the flow of helium and holes for lift pins. Such holes may be formed before or after the protective layer 136 is bonded to the ceramic body. The second metal bond 308 may be substantially similar to the first metal bond 304 , and may have been generated using a room temperature bonding process (e.g., using an ignitable reactive foil). In one embodiment, the reactive foil has preformed foil features that correspond to surface features of the protective layer and/or the ceramic body. For example, the reactive foil may have preformed holes that correspond to helium holes and lift pin holes in the protective layer. Reactive foil having preformed foil features is described in greater detail below with reference to FIGS. 8A-11 .
[0042] In one embodiment, both the first metal bond 304 and the second metal bond 308 are formed at the same time. For example, the entire structure may be pressed together in a fixture, and reactive foil between the thermally conductive base and ceramic body may be activated at approximately the same time as reactive foil between the protective layer and the ceramic body to form both metal bonds in parallel. Bond thickness may be approximately 25 microns to 500 microns (e.g., 150 to 250 microns in one embodiment).
[0043] The thickness of protective layer 136 may be selected to provide desired dielectric properties such as a specific breakdown voltage. In one embodiment, when the electrostatic chuck is to be used in a Columbic mode, the protective layer has a thickness of between about 150-500 microns (and about 200-300 microns in one example embodiment). If the electrostatic chuck is to be used in a Johnson Raybek mode, the protective layer may have a thickness of around 1 mm.
[0044] As mentioned above, the protective layer 136 is a bulk sintered ceramic. In one embodiment, the protective layer is a ceramic composite as described above, which has a high hardness that resists wear (due to relative motion because of thermal property mismatch between substrate & the puck) during plasma processing. In one embodiment, the ceramic composite provides a Vickers hardness (5 Kgf) between about 5 GPa and about 11 GPa. In one embodiment, the ceramic composite provides a Vickers hardness of about 9-10 GPa. Additionally, the ceramic composite may have a density of around 4.90 g/cm3, a flexural strength of about 215 MPa, a fracture toughness of about 1.6 MPa·m 1/2 , a Youngs Modulus of about 190 GPa, a thermal expansion of about 8.5×10 −6 /K (20-900° C.), a thermal conductivity of about 3.5 W/mK, a dielectric constant of about 15.5 (measured at 20° C. 13.56 MHz), a dielectric loss tangent of about 11×10-4 (20° C. 13.56 MHz), and a volume resistivity of greater than 10 15 Ω·cm at room temperature in one embodiment.
[0045] In another embodiment, the protective layer is YAG. In another embodiment, the protective layer is sapphire. In still another embodiment, the protective layer is yttrium aluminum oxide (Y x Al y O z ).
[0046] A gasket 310 may be disposed at a periphery of the electrostatic chuck 150 between the protective layer 136 and the ceramic body 302 . In one embodiment, the gasket 310 is a fluoro-polymer compressible o-ring. In another embodiment, the gasket is a liquid polymer that cures under pressure to form the gasket. The gasket 310 provides a protective seal that protects the metal bond 308 from exposure to plasma or corrosive gases. A similar gasket may encircle and protect the first metal bond 304 . Note also that a similar type of gasket 314 may be used to seal off and separate the electrode connection 306 from the first metal bond 304 .
[0047] A quartz ring 146 , or other protective ring, surrounds and covers portions of the electrostatic chuck 150 . The substrate 144 is lowered down over the electrostatic puck 166 , and is held in place via electrostatic forces.
[0048] If the electrostatic chuck 150 is to be used for Columbic chucking, then the thickness of the protective layer (dielectric above the electrode) may be about 200 microns to about 1 mm. If the electrostatic shuck 150 is to be used for Johnson Raybek chucking, then the thickness of the protective layer may be about 1 mm to about 1.5 mm.
[0049] FIG. 4 illustrates a cross sectional side view of one embodiment of an electrostatic chuck 400 . The electrostatic chuck 400 has a ceramic body 410 metal bonded to a protective layer 415 by a metal bond 420 and further bonded to a metal plate 455 by a silicone bond or other bond 496 . In one embodiment, the ceramic body has a thickness of about 3 mm. The ceramic body 410 may include one or more heating elements 418 . In one embodiment, the ceramic body 410 includes an electrode embedded therein. In another embodiment (as shown), an electrode 485 may be embedded in the protective layer 415 . In yet another embodiment, a metal bond 420 may at as an electrode. In one embodiment, an upper portion 492 of the protective layer 415 that lies above the electrode 485 has a thickness of greater than 200 micron (e.g., 5 mil in one embodiment). The thickness of the upper portion 492 of the protective layer 415 may be selected to provide desired dielectric properties such as a specific breakdown voltage.
[0050] After the protective layer 415 is placed (and ground to a final thickness in some embodiments), mesas 418 are formed on an upper surface of the protective layer 415 . The mesas 418 may be formed, for example, by bead blasting or salt blasting the surface of the protective layer 415 . The mesas may be around 3-50 microns tall (about 10-15 in one embodiment) and about 200 microns in diameter in some embodiments.
[0051] Additionally, multiple holes 475 are drilled through the ceramic body 410 and/or protective layer 415 . These holes 475 may be drilled before or after the protective layer 415 is bonded to the ceramic base 410 , and holes in the protective layer 415 may line up with holes in the ceramic body 410 and/or base 455 . In one embodiment, holes are drilled through the protective layer 415 , ceramic body 410 and base 455 after the bonding is performed. Alternatively, holes may be drilled separately and then aligned prior to bonding. The holes may line up with preformed holes in a reactive foil used to form the metal bond 420 between the ceramic body 410 and protective layer 415 . In one embodiment, gaskets 490 are placed or formed at a perimeter of the metal bond 420 and where the holes 475 meet the metal bond 420 . The gaskets formed around the holes 475 may be omitted in some implementations in which the metal bond 420 is not used as an electrode. In one embodiment, the holes 475 have a diameter of about 4-7 mil. In one embodiment, the holes are formed by laser drilling. The holes 475 may deliver a thermally conductive gas such as helium to valleys or conduits between the mesas 418 . The helium (or other thermally conductive gas) may facilitate heat transfer between a substrate and the electrostatic chuck 400 . It is also possible to deposit the mesas 418 on top of substrate support (e.g., onto the protective layer 415 ). Ceramic plugs (not shown) may fill the holes. The ceramic plugs may be porous, and may permit the flow of helium. However, the ceramic plugs may prevent arcing of flowed plasma.
[0052] FIG. 5 illustrates one embodiment of a process 500 for manufacturing an electrostatic chuck. At block 505 of process 500 , a ceramic body is provided. The provided ceramic body may be a ceramic wafer. The ceramic wafer may have undergone some processing, such as to form an electrode connector, but may lack heating elements, cooling channels, and an embedded electrode.
[0053] At block 510 , a lower surface of the ceramic body is bonded to a thermally conductive base by performing a metal bonding process to form a first metal bond. At block 515 , a bulk sintered ceramic protective layer is bonded to an upper surface of the ceramic body by the metal bonding process to form a second metal bond. The protective layer may be a ceramic wafer having a thickness of about 700 microns to about 1-2 mm. The metal bonding process is described with reference to FIG. 7 . In one embodiment, the upper surface of the ceramic body is polished flat before bonding it to the protective layer. At block 520 , the second metal bond is coupled to a sealed electrode connection. This coupling may occur as a result of the metal bonding process that forms the second metal bond.
[0054] At block 525 , a surface of the protective layer is ground down to a desired thickness. The protective layer may be a dialectic material over a clamping electrode, and so the desired thickness may be a thickness that provides a specific breakdown voltage (e.g., about 200-300 microns in one embodiment).
[0055] At block 530 , mesas are formed on an upper surface of the protective layer. At block 535 , holes are formed in the protective layer and the ceramic body (e.g., by laser drilling). Note that the operations of block 530 may be performed after bonding the protective layer to the ceramic body (as shown), or may be performed prior to such bonding. Plugs may then be formed in the holes. In an alternative embodiment, the ceramic body may be bonded to the base after the mesas are formed, after the holes are formed and/or after the protective layer is bonded.
[0056] FIG. 6 illustrates another embodiment of a process for manufacturing an electrostatic chuck. At block 605 of process 600 , a ceramic body is provided. The provided ceramic body may be a ceramic puck that includes one or more heating elements. The ceramic puck may or may not include an embedded electrode.
[0057] At block 610 , a lower surface of the ceramic body is bonded to a thermally conductive base. The bond may be a silicone bond in one embodiment. In another embodiment, the bonding material may be a thermal conductive paste or tape having at least one of an acrylic based compound and silicone based compound. In yet another embodiment, the bonding material may be a thermal paste or tape having at least one of an acrylic based compound and silicone based compound, which may have metal or ceramic fillers mixed or added thereto. The metal filler may be at least one of Al, Mg, Ta, Ti, or combination thereof and the ceramic filler may be at least one of aluminum oxide (Al 2 O 3 ), aluminum nitride (AlN), titanium diboride (TiB 2 ) or combination thereof.
[0058] At block 615 , a bulk sintered ceramic protective layer is bonded to an upper surface of the ceramic body by a metal bonding process to form a metal bond. The metal bonding process is described with reference to FIG. 7 .
[0059] At block 620 , a surface of the protective layer is ground down to a desired thickness. The protective layer may be a dialectic material over a clamping electrode, and so the desired thickness may be a thickness that provides a specific breakdown voltage.
[0060] At block 625 , mesas are formed on an upper surface of the protective layer. At block 630 , holes are formed in the protective layer and the ceramic body (e.g., by laser drilling). In an alternative embodiment, the ceramic body may be bonded to the base after the mesas are formed, after the holes are formed or after the protective layer is bonded.
[0061] FIG. 7 illustrates one embodiment for performing a metal bonding process. At block 705 , a surface of a first body is coated with a first metal layer. The metal layer may be tin, indium or another metal. At block 710 , a surface of a second body is coated with a second metal layer. The first body and second body may be, for example, a protective layer, a ceramic body or a thermally conductive base. For ceramic bodies (e.g, the ceramic body or protective layer), coating the surface with a metal layer may include first forming a titanium layer on the surface. Titanium has properties that cause it to form strong bonds with ceramics (such as by forming bonds with oxygen molecules in ceramics). A metal layer may then be formed over the titanium.
[0062] The metal layer may be tin or indium, for example. If tin is used for the metal layer, then processes of below 250 degrees C. may be performed using the electrostatic chuck since tin has a melting temperature of 250 degrees C. If indium is used for the metal layer, then processes of below 150 degrees C. may be performed using the electrostatic chuck since indium has a melting temperature of 150 degrees C. If higher temperature processes are to be performed, than a metal having a higher melting temperature should be used for the metal layers. The titanium layer and the subsequent metal layer may be formed by evaporation, electroplating, sputtering, or other metal deposition or growth techniques. Alternatively, the first metal layer may be a first sheet of solder (e.g., a sheet of tin or indium) that is positioned against the first body, and the second metal layer may be a second sheet of solder that is positioned against the second body. In one embodiment, the first metal layer and second metal layer are each approximately 1-20 mils thick (e.g., 25-100 microns in one embodiment).
[0063] At block 715 , a gasket is applied on a periphery of the coated surface of the first body or second body. The gasket will protect the coated surface from interaction with corrosive gases or plasmas. In one embodiment, the gasket is a compressible o-ring. Alternatively, the gasket may be a liquid that cures under pressure to form the gasket.
[0064] At block 720 , the coated surface of the first body is positioned against the coated surface of the second body with a reactive foil therebetween. In one embodiment, the reactive foil is approximately 50-150 microns thick. At block 725 , pressure is applied to compress the first body against the second body. The pressure may be about 50 pounds per square inch (PSI) in one embodiment. While the pressure is applied, at block 730 the reactive foil is activated. The reactive foil may be activated by providing a small burst of local energy, such as by using optical, electrical or thermal energy sources. Ignition of the reactive foil causes a chemical reaction that produces a sudden and momentary localized burst of heat up to about 1500 degrees C., which melts the first and second metal layers, causing them to reflow into a single metal bond. This nano-bonding technique for forming a metal bond precisely delivers localized heat that does not penetrate the bodies being bonded. Since the bodies are not heated, the bodies may have a significant mismatch in coefficients of thermal expansion (CTE) without a detrimental effect (e.g., without inducing stress or warping).
[0065] FIG. 8 illustrates one embodiment of a process 800 for manufacturing a reactive foil sheet having preformed foil features. At block 805 of process 800 , a template having surface features is provided. The template may be any rigid material in one embodiment. The template may have a substantially planar surface, with one or more surface features. Alternatively, the template may have a non-planar surface with or without surface features.
[0066] The surface features may include positive steps (e.g., standoffs) and/or negative steps (e.g., holes or trenches) in a surface of the template. The steps may have a height or depth that is sufficient to cause a first portion of a deposited reactive foil sheet that covers the step to be discontiguous with a second portion of the reactive foil sheet that covers a remainder of the template. For example, standoffs may have a height of about 1-25 mm, and holes/trenches may have a depth of about 1-25 mm In one particular embodiment, the steps have a height or depth of about 2-10 mm Instead, deposited reactive foil may have the shape of the non-planar regions.
[0067] The surface features may also include non-planar regions such as bumps, dips, curves, and so forth. These surface features may not cause any portions of a deposited reactive foil sheet to be discontiguous with other portions of the reactive foil sheet.
[0068] At block 810 , alternating nanoscale layers of at least two reactive materials are deposited onto the template to form a reactive foil sheet. In one embodiment, the reactive materials are metals that are sputtered onto the template. The reactive materials may also be formed by evaporation, electroplating, or other metal deposition or growth techniques. Thousands of alternating layers of the two reactive materials may be deposited onto the template. Each layer may have a thickness on the scale of one nanometer to tens of nanometers. In one embodiment, the reactive foil is approximately 10-500 microns thick, depending on the number of nanoscale layers that the reactive foil includes. In a further embodiment, the reactive foil is about 50-150 microns thick.
[0069] In one embodiment, the two reactive materials are aluminum (Al) and nickel (Ni), and the reactive foil is a stack of Al/Ni layers. Alternatively, the two reactive materials may be aluminum and titanium (Ti) (producing a stack of Al/Ti layers), titanium and boron (B) (producing a stack of Ti/B layers), copper (Cu) and nickel (producing a stack of Cu/Ni layers) or titanium and amorphous silicon (Si) (producing a stack of Ti/Si layers). Other reactive materials may also be used to form the reactive foil.
[0070] For some surface features, a height or depth of the surface feature may cause a portion of a deposited reactive foil sheet to be discontiguous with other portions of the reactive foil sheet. In many cases, this discontinuity is intended. However, if no discontinuity is desired, then an angle of the template with regards to a deposition source may be controlled to eliminate any such discontinuity. In one embodiment, the template is rotated and/or the angle of the template with relation to the deposition source is changed during the deposition process. In another embodiment, multiple deposition sources having different locations are used. The arrangement of the deposition sources may be set to maximize coverage of a non-planar surface and/or surface features while minimizing thickness variations in the alternating layers.
[0071] At block 815 , the reactive foil sheet is removed from the template. The reactive foil sheet may have a weak mechanical bond to the template, enabling the reactive foil to be removed from the template without tearing. The reactive foil sheet may have foil features that correspond to surface features of the template. For example, the reactive foil sheet may have voids corresponding to the regions of the template that had steps. Additionally, the reactive foil sheet may have non-planar (e.g., three dimensional) features corresponding to three dimensional features in the template. The features may have various sizes and shapes. The preformed foil features may correspond to surface features of one or more substrates that the reactive foil is designed to bond. Accordingly, the formed reactive foil may be production worthy. For example, the reactive foil may be set in place on a substrate having surface features and energized to create a metal bond without first machining the reactive foil to accommodate the surface features.
[0072] FIG. 9A illustrates deposition of nanoscale metal layers onto a template 900 having surface features. The template 900 has a substantially planar surface 905 with three surface features 910 , 915 , 922 . Surface features 910 and 915 are steps having a height 920 . The height 920 is sufficiently tall to cause nanoscale metal layers deposited 925 onto the features 910 , 915 to be discontiguous with nanoscale metal layers deposited 925 onto a remainder of the template's surface 905 . Surface feature 922 is a non-planar (e.g., three dimensional) feature. Metal layers 925 deposited onto feature 922 are contiguous with metal layers deposited onto the remainder of the template's surface 905 .
[0073] FIG. 9B illustrates a reactive foil sheet 950 having preformed foil features 960 , 965 , 970 . The reactive foil sheet 950 is formed by depositing alternating nanoscale metal layers onto template 900 of FIG. 9A . The reactive foil sheet 950 is substantially planar. However, reactive foil sheet 950 includes a non-planar feature 970 caused by deposition over surface feature 922 of template 900 . Foil features 960 and 965 are voids in reactive foil sheet 950 , and correspond to surface features 910 , 920 of template 900 .
[0074] FIG. 10A illustrates deposition of nanoscale metal layers onto a template 1000 having a non-planar surface 1005 . The template 1000 may have a three dimensional shape as shown, or may have any other three dimensional shape. FIG. 10B illustrates a non-planar reactive foil sheet 1050 having a three dimensional shape that matches the three dimensional shape of template 1000 . This three dimensional shape may correspond to a three dimensional shape of two substrates that the reactive foil will be used to bond together. Accordingly, the reactive foil sheet 1050 may be place onto one of the substrates in an orientation and position that causes a shape and any features of the reactive foil sheet 1050 to line up with a shape and features of the substrate. The second substrate may then be placed over the reactive foil sheet, and the reactive foil sheet may be ignited. Because the reactive foil sheet has a shape that matches the substrates that it will bond, the reactive foil sheet will not be deformed or torn. This may minimize or eliminate leakage paths that might otherwise be caused by attempting to use a planar reactive foil sheet to bond non-planar surfaces.
[0075] The reactive foil sheets with preformed features described herein may be used to bond any two substrates. The reactive foil sheets may be particularly useful for applications in which a room temperature, rapid bond is to be formed without vacuum and between substrates having surface features. For example, the reactive foil may be used to bond an electrostatic puck with helium holes to a cooling base plate. The reactive foil sheets described herein may also be used to bond a protective layer over a showerhead, which may have thousands of gas distribution holes as well as divots and/or standoffs around the gas distribution holes. The reactive foil sheets may also be used to bond semiconductor devices, solar devices, and other devices.
[0076] FIG. 11 illustrates a continuous reactive foil 1100 formed of interlocking reactive foil sheets 1105 , 1110 , 1115 , 1120 . The perimeters of the reactive foil sheets 1105 - 1120 may have a tessellating puzzle shape that enables the reactive foil sheets 1105 - 1120 to interlock. The tessellating puzzle shape may be formed by depositing alternating nanoscale metal layers over a template having a step around a perimeter of the template with the tessellating puzzle shape. Accordingly, the above described process 800 may be used to create interlocking reactive foil sheets. These interlocking reactive foil sheets enable any sized substrate to be bonded using a metal bonding process without introducing leakage pathways.
[0077] The preceding description sets forth numerous specific details such as examples of specific systems, components, methods, and so forth, in order to provide a good understanding of several embodiments of the present invention. It will be apparent to one skilled in the art, however, that at least some embodiments of the present invention may be practiced without these specific details. In other instances, well-known components or methods are not described in detail or are presented in simple block diagram format in order to avoid unnecessarily obscuring the present invention. Thus, the specific details set forth are merely exemplary. Particular implementations may vary from these exemplary details and still be contemplated to be within the scope of the present invention.
[0078] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrase “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. In addition, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” When the term “about” or “approximately” is used herein, this is intended to mean that the nominal value presented is precise within ±10%.
[0079] Although the operations of the methods herein are shown and described in a particular order, the order of the operations of each method may be altered so that certain operations may be performed in an inverse order or so that certain operation may be performed, at least in part, concurrently with other operations. In another embodiment, instructions or sub-operations of distinct operations may be in an intermittent and/or alternating manner In one embodiment, multiple metal bonding operations are performed as a single step.
[0080] It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to design method of network configurations for data input/output (I/O) management in a computer network system. More particularly, this invention relates to design method of network configurations for managing data search and retrieval wherein an experience-based automatic link generation is implemented on hierarchical hyper-document networks which is facilitated by employing a user profile filter database.
2. Description of the Prior Art
In performing a task of data search and retrieval on an automatic link generation network system, user's need is either ignored or a requirement is imposed on an user to explicitly enter a set of key words and queries to invoke specific system actions. Among the searched documents distributed in a plurality of networked databases, a user's task to search and retrieval relevant information is often confronted with two conflicting considerations. The processing time can be reduced and the retrieval can be expeditiously completed by entering single key words and documents shared these single key words can be easily located. However, this type of search on a network often generates two many links and the documents retrieved by use of this method are of low search precision. On the other hand, a search can be performed among these networked data bases by applying a duster of key words and only documents which share those duster keywords are retrieved. This type of search can usually achieve higher precision but requires longer processing time and workable only with processors with higher level of processing power. Due to these difficulties, in an automatic link generation networked system, a user's interest for retrieval of relevant information is generally not satisfied in searching multiple documents distributed in several connected nodes.
One method to reduce the disorientation of automatic link generation is to limit the number of links or by attaching attributes to the links. The pre-assigned link attributes are then employed to group, sort, and filter a link generation request, Due to the pre-assignment nature of these link attributes, a user's interest is often ignored. The organization and filtering in link generation in response to a user's search request by employing the pre-assigned link attributes may not directly related or even relevant to a user's search interest since the link attributes which are pre-assigned are not directly correlated with the search undergoing with user's specific request and search patterns or profiles. The pre-assigned link attributes therefore can not reflect the experiences and special interest of the user applying the networked system for information search and data retrieval.
Therefore, there is still a need in the art of configuration design and management of the networked processors and databases for enhancement of information retrieval to implement an improved and novel link generation management system. The automatic link generation management system must be able to directly and dynamically respond to a user's real time requests by continuously and interactively updating and referencing to user specific experience-based link profile. A user's interest including the past search patterns and accumulated link attributes generated during the entire history of searches can be My applied to facilitate the automatic link generation.
SUMMARY OF THE PRESENT INVENTION
It is therefore an object of the present invention to provide an improved network configuration management system capable of interactively and dynamically performing automatic link generation in response to a user's requests for data retrieval from a plurality of networked processors and databases such that the aforementioned difficulties and limitations in the prior art can be overcome.
Specifically, it is an object of the present invention to provide a network configuration management system capable of interactively and dynamically performing automatic link generation in response to a user's requests for data retrieval from a plurality of networked processors and databases wherein the link generation is performed by using a user link profile of the exiting links such that the user interests are fully accounted for.
Another object of the present invention is to provide a network configuration management system capable of interactively and dynamically performing automatic link generation in response to a user's requests for data retrieval from a plurality of networked processors and databases wherein the links are generated with flexible anchor granularity.
Another object of the present invention is to provide a network configuration management system capable of interactively and dynamically performing automatic link generation in response to a user's requests for data retrieval from a plurality of networked processors and databases wherein the links are generated interactively whereby a user can have real-time control over the link generation and the entire search processes.
Briefly, in a preferred embodiment, the present invention includes a networked data-handling system including a plurality of processor-database units wherein each includes a plurality of structured data objects. Each structured data object contains retrievable user requested data therein. The networked system includes an user interface for allowing an user to enter and modify a data retrieval request based on a plurality of profile models, profile modifications and link instructions. The networked system further includes a link generator for receiving and executing the data retrieval request based on the profile models, profile modifications and the link instructions for generating links between the structured data object distributed among the networked processor-database units for retrieving the retrievable user requested data from the linked structured data object. The link generator flier includes a user profile generating means for accumulating and employing the profile models, profile modifications and link instructions for generating a user profile filtering file. The link generator further includes an experience-based link creating means for applying the accumulated profile models, profile modifications, and link instructions and the user profile filtering file for generating a recommended links.
It is an advantage of the present invention is that it provides a network configuration management system capable of interactively and dynamically performing automatic link generation in response to a user's requests for data retrieval from a plurality of networked processors and databases wherein the link generation is performed by using a user link profile of the exiling links such that the user interests are fully accounted for.
Another advantage of the present invention is that it provides a network configuration management system capable of interactively and dynamically performing automatic link generation in response to a user's requests for data retrieval from a plurality of networked processors and databases wherein the links are generated with flexible anchor granularity.
Another advantage of the present invention is that it provides a configuration management system capable of interactively and dynamically performing automatic link generation in response to a user's requests for data retrieval from a plurality of networked processors and databases wherein the links are generated interactively whereby a user can have real-fie control over the link generation and the entire search processes.
These and other objects and advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following defied description of the preferred embodiment which is illustrated in the various drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block diagram showing the system configuration of a networked data processing system of the present invention;
FIG. 2 is a functional block diagram of an automatic link generator of the present invention;
FIG. 3 shows the structure of a hypermedia documents;
FIG. 4 shows the hierarchical tree structure of the hypermedia document;
FIG. 5 shows the discriminating terms selected by the indexer;
FIG. 6A shows a hyper media display;
FIG. 6B shows a link creation process;
FIG. 6C shows the process that a user continues the linking process;
FIG. 6D shows the completed node connection between a source to a destination node;
FIG. 6E the functions performed by a link manager;
FIG. 6F shows the pictorial view of link generation processes;
FIG. 7 shows an icon of a hypermedia display;
FIG. 8 shows a control panel for link modification; and
FIG. 9 shows an the control panel provided to the user interface.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a functional block diagram for illustrating the network configurations at three stages according to the operations performed by an automatic link generator of the present invention. The automatic link generator is implemented in a networked data handling system 10 for generating hypermedia links 12-1, 12-2, 12-3, etc., as that shown in the third stage of the network configuration. The networked data-handling system 10 includes a plurality of processor-database units, e.g., 15-1 to 15-N where N is a positive integer. In the first stage, i.e., stage-I, a user browses several hypermedia documents in the networked data-handling system 10 and identifies two hypermedia nodes, e.g., hypermedia nodes 18-1 and 18-2 which the user considers a link between the contents of these two documents would suit the objectives of searches on this networked data handling system 10. In the second stage, i.e., stage-II, the user creates a user generated link 17 to link the user selected hypermedia nodes 18-1 and 18-2. Then in the third stage, i.e., stage-3, a link generator of the present invention generates a plurality of hypermedia links 12-1, 12-2, 12-3, etc., by employing user selected similarity threshold values which will be discussed below in more details.
In order to carry out the automatic link generation function as described above, a link generating system ,i.e., the HieNet link generator is developed. The HieNet system includes several primary modules to carry out several functions. The first primary functional module is a preprocessing module to preprocess a document. The following processes are performed on a document during a preprocess functional step to prepare a document node for automatic link generation according to the present invention.
a) Term Elimination
All terms in the document which are included in a stop-word list, e.g., "the", "and", "or", "etc.", etc. are eliminated and excluded from being processed in the link generation process. A user can modify the stop-word list by supplying a different stop-word list.
b) Term Frequency Calculation
The term frequencies of the remaining terms are counted and the final total number of occurrence for each term is kept in a separate record.
c) Vector Term Selection
A default number of terms, e.g., one-hundred terms, with their term frequencies closest to the median term frequency are selected for use as a term vector of the document.
d) Vector Term Weight Calculation
A weight calculation is performed for each vector term is by applying a post-order, i.e., a bottom-up, traversal of the document tree. By applying a post-order traversal of the document tree, i.e., a bottom up sequence along the tree, a very efficient weight computation is carried out since the computations are performed only for the leaf nodes on the document tree. Non-leaf nodes receive the weight credits from each of their leaf nodes. Lower level nodes therefore propagate weights upward along the hierarchical document tree. More details for calculating the vector term weights are described below.
e) Size Calculation
In the same step, the node size, i.e., the total number of words, are calculated. Again, only leaf nodes require the side calculation, since the sizes of the non-leaf nodes can simply be obtained by summing up the sizes for each of their children.
A second functional module is an automatic link generation module. A link is created on a node in the document tree if and only if none of its children nodes have links already been generated. The HieNet link generator applies a pre-order, i.e., a top down order, tree traversal to create a link on a node that is as small as possible. Only when an attempt fails, then the link generator processes links for a larger size node. It is for the purpose to allow a user to identify the smallest possible nodes during the generation of links such that a user only has to deal with smallest mount of data for relevant information. Under the circumstances that a user desires to see links for larger bodies of texts, HieNet link generator provides a slider bar for controlling the node size for link generation as that shown in FIG. 6C for a "Control Panel for Automatic Link Generation".
A third functional module is a user controlled dynamic link generation module. HieNet provides two slider bars in this module. The first slider bar is for the user to control the node similarity threshold and the second slider bar is for controlling the node size. Again please refer to FIG. 6C for the Control Panel for Automatic Link Generation. By default, HieNet generates a link with a pair of smallest nodes that satisfies both the similarity threshold and node size parameters. There is no fixed constrain on node granularity and depending on the threshold and node size, the node granularity can vary greatly. For example, the automatic generated links can be established from paragraphs to sections, chapters, books, or vice versa.
HieNet checks if the current node has a similarity measure above the threshold. Only then does it traverse to the descendants of that node; otherwise the sub-tree of that node is ignored completely. Since all the relevant information in that branch for all the nodes below have already propagated their term weights upward to each of the parent nodes, once a document node is determined to have relevant data below a threshold value, all the nodes in the branches below can be skipped without losing links that would have satisfied the similarity threshold. After a node is determined that a similarity threshold is satisfied, the node size is checked to determine if an automatic link should be generated.
With this intelligent pruning heuristics, the time complexity required for generating links is drastically lowered than the prior art methods which is typically in the order of O(n). Thus, the user is able to interactively change these parameters and obtains an expeditious response of dynamically created links. The highly interactive nature of these user requests and automatic generated links makes the approach practically useful. The quality of the system generated links based on lexical co-occurrence is fundamentally limited by the range and consistency of words used by the document authors. Users need some trial-and-error to adjust the linking parameters so that the system will create reasonable links without also creating too many remotely relevant associations between large amount of documents searched.
Please refer to FIG. 2 for the major components of a hypermedia link management system and the functions performed by these major components for the automatic link management and generation processes. For the very first time all hypermedia documents are retrieved from the hypermedia database 106 by the I/O controller 105 of the hypermedia link management system 100 through the network connection 301. These documents are processed and indexed by the preprocessing module as described above. After this one-time process, the indexes including the term vectors, term frequencies, node size and all relevant information relating to the documents for document search and link generation are stored in an associated document record. This is a one-time process and only the brand new hypermedia documents are required to be pre-processed. For link generation, the hypermedia documents are down loaded through an internal bus 303 to a structure reader 104. The hypermedia document is decomposed by the structure reader 104 into document nodes, i.e., hierarchical data objects according to a document tree structure as that shown in FIG. 4. Then the indexer applies various indexing methods to create indexing information for different kinds of hypermedia objects and nodes, such as indexes for graphics data, audio data, or textual data. The link generator 101 then selects discriminating terms based on term frequencies or other term selection criteria as that exemplified in FIG. 5. A term vector consists of these discriminating terms are computed for every node of each of the document tree. Each entry in the vector represents the weight for a discriminator. For each node or object, the term vector is calculated by calculating a term weigh per entry in the term vector. Leaf nodes are calculated first and the weights are propagated bottom up to a parent node. The resulting term vector is then stored for each node as a separate record.
After the hypermedia documents are retrieved by the I/O controller 105, these documents are sent to the personal computers (PC), e.g., PC 107 to 109, via internal bus 203 and local area network 204. The hypermedia documents are displayed on user's computer screen as that shown in FIG. 6A and FIG. 9.
The major thrust of the present invention is to provide a link generator 101 which generates new links automatically based on existing user-created links. The process starts with a user selects a source node from a hypermedia document as that shown in FIG. 6B, and then the user selects a second document node as a destination node as shown in FIG. 6C. Once the source node and destination nodes are selected, a user created node, e.g., link 17 as that shown in FIG. 1, is generated by the links generator 101 (please referring to FIG. 6D). A user is provided with the flexibility to create a link across the network into other remote hypermedia management system 110 via connection 302 and Internet 205. Connection 302 to the Internet system 205 allows the links to be created across the network and also allows the links to be shared and distributed across the networks.
The user created link 17 is transferred from user's PC, e.g., PC 107 to 109, to the link manager 102 via the connection wire 201. The link manger 102 calculates the link profile for the user created link and stores the results in an internal cache. The link profile contains information such as date, link types, e.g., graphics, textual, audio, etc., and identifications, unique addresses and term vectors of the nodes. Please referring to FIG. 6E for an example of link profile for a user created link, e.g., link 17 in FIG. 1. The link generator 101 the employs The link profile generated by the link manager 102 is transferred to the link generator 101 via a data bus cable 306. The link generator 101 the employs the link profile and the indexing information from the hypermedia data base 106 to start an automatic link generation process as that shown in FIG. 6F. All the pairs of documents nodes in the hypermedia database 106 which have similarity between them that matches the similarity threshold are selected as source and destination nodes and an automatic system generated link is constructed. The similarity between two document nodes is calculated by taking the inner product of their corresponding term vectors. By default, the link generator 101 tries to link with smallest possible pair of source and destination nodes. All system generated links are transferred back to the link manager 102 and stored in the link cache via data bus 307. The resulting links generated by the link generator 101 are also displayed in a user's computer 107 to 109 as that shown in FIG. 7.
A user is provided with the option to open the links by clicking on the link icons. The user's requests to open and review the links are sent to the link manager 102 and the contents of the links are sent to each computer 107 to 109 via data bus 202 and 204. After a user reviews the contents of the links, a user may then adjust the link generation, such as similarity threshold and node size. The user changes of the link generation parameters can be entered through the control panel as that shown in FIGS. 8 and 9. The link generator 101 then interactively generates new sets of links according to new link parameters provided by the user as that shown in FIG. 9. Table 1, on the last page of the specification, summaries the functions performed by each of the functional blocks shown in FIG. 2.
Referring to FIG. 3 for the structure of a hypermedia document. A hypermedia document can be decomposed into a plurality of objects or nodes. The document node, e.g., a chapter, as shown in FIG. 3 includes five objects which are "chapter", "section", "paragraph a" and "paragraph b". The actual text are omitted for the purpose of simplicity of illustration. FIG. 4 shows the tree-type hierarchical structure of a objects or nodes. The hierarchical tree structure consists of objects or nodes of different sizes thus constituting a hypermedia document. One particular advantage of the present invention is that the automatically generated links can link nodes of different granularity, i.e., the links can be between two nodes of every kinds of objects, e.g., a book-to-a paragraph, a chapter to a section etc. Unlike the restrictions in some of the prior art systems where the nodes are limited to simple text chunks. The text objects of the present invention are provided with unique identification (ID) and other attributes thus greatly increasing the flexibility in linking nodes of different granularity.
Referring to FIG. 5, the indexer 103 as shown in FIG. 2 selects the discriminating terms based on the frequencies of these terms. The terms with high frequencies of occurrence represent discriminating features of the document. The discriminating terms as shown in FIG. 5 are selected from 16,000 words. In this example, seven articles relating to Los Angeles riots are transcribed from Newsweek and Time Magazines. Two chapters of object-oriented (00) C++ graphics manuals are intermingled with these seven articles. In FIG. 5, the top four terms are color, model, black and value. These terms are commonly used in these articles.
In FIG. 6A hypermedia documents are displayed on a computer screen to provide to a user a visual representation of the documents available through the network system. With these documents accessible to a user, selection is made in FIG. 6B where a user identifies a source document. In this example, the user selects an source node which includes discriminating terms such as "hours", "men", and "street". Then in FIG. 6C, a user selects a destination node for establishing a link between the source node and the destination node. In this example, the article selected by the user includes discriminating terms of "rioting", and "talking" shown as part of the textual content in this destination node. Upon a user's command, a user created link is established as that shown in FIG. 6D thus linking the source node to the destination node. For this user created link, the link manager 102 then calculates the link profile. As shown in FIG. 6E the link profile is a table includes the link creation date, the link owner, the link type, identification, unique addresses and the term vectors. The definitions of the term vectors will be further described below.
With this user created link and the link profile as that shown in FIG. 6E, a plurality of system generated links linking a plurality of pairs of source-and-destination nodes which satisfy the similarity threshold Criterion and the node size requirement, are established as shown in FIG. 6F. According to the table shown in FIG. 6F, two system generated links are established to link two pairs of source and destination nodes. The terms which contribute to high term weights in the term vector for linking these two pairs among these articles are "hour", "men", and "street" for the source node, and "shot", "burn", "talking", "riot", and "rioting". A screen display is shown in FIG. 7 as an example of the system generated links. A special icon "→" is shown to indicate that there are system generated links established and a pop-up window is used to display that a list of link destination. The order of the list is based on the result of relevance ranking calculated with term vector weights as explained below. The link manager 102 and link generator 101 also provide a control panel as shown in FIG. 8 for a user to control the link generation process and to adjust the link generation parameters such as the node size and the similarity threshold. FIG. 9 shows an exemplary search results displayed on a user's computer monitor. In addition to the control panel, the system generated links including two hypermedia documents and associated link profile parameters are also shown in this display. A user is provided with a comprehensive graphic interface to perform the document search and linking processes.
According to the present invention, when a user entered a data retrieval request by entering a source node linking to a destination node, and link instructions, the automatic link generator make use of the user created links to generate a user preferred `link profile`. The Link Profile is analogous to the fisherman's net that catches fish in the water. Depending on the type or size of the networked system, different fishes, i.e., documented data, are caught and retrieved. Similarly, the link generator in the invention builds a `information agent` that applies the Link Profile to catch relevant information and bring it back to a user's personal information space. The user can create Link profiles for any given occasion. For example, a user may create a new Link Profile which is used in an art class and save the Link Profile for other art-related hypertext documents. The user may also load any Link Profile as a model profile and generates new Link Profile based on the information and indices contained in the model profile.
A running model can be built on a hypermedia document structure where the test representation is based on the Standard Generalized Markup Language (SGML) which is becoming a popular document exchange format and hyper-document structure. Many popular tools and system functions are now available on the market. Therefore, this invention can implemented as efficient and practical procedures on a system which includes documents in commonly used SGML format. A running model of this invention is built on top of a version of DynaText which is used in Brown University. The details of DynaText features are described in `HieNet: A User Centered Approach for Automatic Link Generation` (Hypertext 93 Proceedings, November 93 PP. 145-158 by Daniel T. Chang). The information included in that paper is incorporated by reference.
As FIGS. 2 to 9 are provided for illustrating the processes performed by the link generator 101 and link manager 102. The details of content representations of each node by attributes and the calculation by the use of Salton's Vector Space Model are fully described below and can be easily referenced to an article by the present Applicant which is incorporated as reference herein and attached as part of the Application. The details of link profile vector and similarity threshold computations and evaluations are also described below to fully disclose the novelty of the present invention.
As one can appreciate that most hypertext systems facilitate one-at-a-time link creation, but only few support automatic link generation. In systems that support automatic link generation, user interests are either ignored or explicit user actions are required to enter a set of keyword and queries. In this invention, a hypermedia link management system is disclosed wherein automatic system generated links are "calculated" and then linked based on a previous created user-links. A user is allowed to control the system generated links by providing similarity thresholds, node granularity and the extent of linking in composite nodes. The term vectors derived from Salton's Space Model are applied for similarity computations. By applying an existing user created link as a basis for similarity computations and threshold evaluation, the hypermedia link management system disclosed in this invention provides automatic system generated links which most closely and adaptively reflect the user experience containing in the user link presented to the link management system.
For a basic understanding of the extent of the invention, the definition of a "node" is broadened to include any structured text object. Unlike the nodes in some systems which are limited to simple text chunks, the text object can contain other objects and it has an unique D and other quantifiable attributes associated with each text object. For example, a text object Chapter can contain several paragraph objects and section objects. The section object, in turn, may contain other objects. By applying the Standard Generalized Markup Language (SGML) as the text representation of the hyper-document structure, no restriction is placed on the node, i.e., text object, granularity. The granularity is a parameterized variable that the use may specify with great deal of flexibility. In SGML structure, a hyper-document is constructed with a tree hierarchy and when a document is managed with a tree structure, the automatic linking process can be performed with a very efficient and practical manner.
An executable program, i.e., HieNet, is built according to the principle of this invention. HieNet is built on top of a version of DynaText used in research at Brown University. DynaText is a hypertext browser of the Electronic Book Technologies, Inc. The DynaText graphical browser consists of a table of contents (TOC), a M-text window for displaying the text and a full text structure based query facility. DynaText requires that a document to be in SGML structure in order to index and format the document as an on-line hypertext. A document is typically marked up in SGML by employing a plurality of "tags" to delineate the structure as chapter, section, subsection, etc. By the use of these tags, DynaText extracts the hierarchical structure to form a tree. A collection of document trees forms a document space. When a user link is provided to the link generator, DynaText extracts and display the elemental attributes of the user generated link. For example, the element
<video num=234> This is a text description of an emergency procedure <video>
specifies a link that originates from this text element to video clip number 234 stored in the database. SGML element tags can be used to indicate the link types by specifying them as values of a link type attribute. Hence, user can view desired links via attribute filters. The structures of the document can also be used as filters. For example, the use can ask, "show me all the video links (links to a piece of video) contained in chapter 2".
The HieNet Link Database
Most research hypertext systems and a few commercial ones store links separately in a database where each link is a record entry in a link table. Several fields/attributes are associated with a link such as address for the source and destination node, link type, link owner and link date. However, no information is generally stored in the link table to describe the content of the nodes.
The version of DynaText on which HieNet is built on still lacks a link database and associated Link manager. A database is first built which is now part of the commercial DynaText product. In addition to the typical link attributes as generally included in a typical system, HieNet adds extra attributes to store the content representation of the link's source and destination nodes as text objects. The content representation now stored by HieNet together with other attributes are employed to define a link profile. A content description for each node is further calculated as a vector by using a Salton Vector Space Model.
Salton's Vector Model
Representing Node Content as a Vector
Give a text node Di, a content representation may be given as a term vector of terms Di=(d i1 , d i2 , . . . , d it ), in which dik represents a term weight of term Tk assigned to node Di. The weight of each term dik is calculated using the heuristic term weight equation which is the term frequency divided by the document frequency, i.e., d ik =tf/df, that assigns high term weights to terms that occur frequently inside a particular node but relatively rarely in the document space L. Note that dik 2 1 since the term frequency, the number of times the term occurs in a document, is at most equal to document frequency, i.e., the number of times the term occurs in the document. Terms with a high term weight known to be important in content identification. Terms occurring with extremely high frequency in the document space turn out to have a very small term weights because their document frequency is extremely high.
Similarity Measure
Given two nodes Di and Dj, a similarity measure can be obtained between items based on the similarity between the corresponding term vectors. The similarity measure can be defined and computed as an inner vector product as: ##EQU1## Updating the Link Profile
Every time the user creates a link, a link instance is added to the Link Profile. This Link Profile records the creator, creation time and link type attributes and most importantly, a pair of term vectors, one for source node and one for the destination node.
HieNet preprocesses the document and composes a term vector for each of the leaf nodes in the tree. The term vector represents the content for each node. In addition, whenever the user creates a link, HieNet uses the term-weight equation, which as defined above as the term frequency divided by the document frequency, i.e., d ik =tf/df, to compose two term vectors, one for the source node and one for the destination node and store them in the Link Profile (please refer to FIG. 6E which illustrates graphically a Link Profile).
Automatic Link Generation Based on the Link Profile
Using the similarity measure equation as that defined in Equation (1), HieNet scans the document space to fine node pairs whose similarity measure matches with the user created links in the Link-Profile. First, any node whose similarity measure with the source vector in the Link Profile is above a certain threshold is put into the source set S. Secondly, the same operation is applied to generate the destination set T. Finally, HieNet creates links between the sets S and T (please refer to FIG. 6F for system generated links).
Automatic Link Generation Based on Node Size
In addition to the similarity threshold, HieNet also takes the node size into consideration. By default, HieNet creates a link with the smallest pair of source and destination nodes that surpass the similarity threshold. A link that is relevant to the user may amount to only two paragraphs in a 400 page document. This is a desirable characteristic which is called the sub-document retrieval capability. However, the user is able to overwrite the default by setting a new node size value for the system generated links in linking these nodes.
Relevance Ranking
Each destination node in the link is assigned a source calculated from the similarity Equation (1). After the system completes the generation of the automatic link, a source node may contain more than one link to various destination nodes. The user is presented with a list of ordered destination nodes with the highest similarity measure displayed on the top of the list with additional nodes arranged in accordance with a relevance ranking order (please refer to FIG. 7 for a browsing window showing such an operation).
User Controlled Parameters
1. Stop-word List
The user can provide to HieNet a list of words to be eliminated at the start of the link generation process. This process is useful in eliminating function words such as "and", "or", and "not" or any other words that occur extremely frequently in the document space ant thus are poor content discriminators because their term weights are extremely small.
2. Vector Term Selection
As a default, HieNet selects a group of terms whose term frequencies are closest to the median term frequency in the document space. Terms with extremely high or low frequency are not selected since their term weights are dose to zero and they are ineffective in the similarity measure calculations. Better term selection generates more relevant links for the user.
3. Link Filter
The user can apply filters to minimize links known to be irrelevant or undesirable as link examples and use the remaining links to generate new links. For example, the user can filter out links created before a certain date or by a certain person, since all the links created in the system have time and creator attributes attached to them.
4. Node (Text Object) Size
The user can adjust the size parameter to view links that contain nodes of a certain size.
5. Similarity Threshold
An interesting consequence of the link generation method of this invention is that when the similarity increases above a certain level the system starts to generating links with larger node size. The reason is that when the size of the nodes becomes larger, the node contains more words and the term frequencies of these words are increased. High term weights are calculated with higher term frequencies which leads to higher similarity measure (please refer to FIG. 8 for the display of a control panel showing the automatic link generation process).
Steps Performed by HieNet in Automatic Link Generation
The steps carried by HieNet in performing an automatic link generation process are described below:
Preprocessing
1. Term Elimination
All terms in the document space specified in the stop word list are excluded from the link generation process. The user is provided with an option to modify the stop word list or to supply a new list,
2. Term Frequency Calculations
The term frequencies of the remaining terms are determined based on a numerical counts of the times a term occurred in the document space.
3. Vector Term Selection
A default number of terms, e.g., 100, for which the occurrence frequencies are closest to the median term frequency are selected for use in the term vector. The user can select different terms.
4. Vector Term Weight Calculation (Post Order Traversal of the Document Tree)
By taking advantage of the hierarchical tree structure of the document space, a post order traversal of the document tree, i.e., a bottom-up, sequence is applied to calculate the term vectors only for the leaf nodes in a document tree. Non-leaf node then obtain the term weight from the credit of the descendant nodes. Thus the term vectors are propagated upwardly in the document space.
The process in computing the term vector is different from a usual card-based link generation system. In a card-based link generation system, the link is only generated between two nodes only if the two nodes by themselves can come up with a similarity measure exceeding a threshold. If the potential link does not pass the similarity threshold, no link is created and the knowledge that a Link had a partial support is discarded. In contrast, in HieNet of this invention, the term vectors are propagated and credited upwardly from lower nodes to their parents. Higher level nodes may accumulate sufficient term frequency to trigger a link generation. Since the term vector computations are carried out only for the leaf nodes, the worst time complexity for term vector calculation is O(n) which is not worse than the time required to index each chunk in a card-based link generation system.
5. Size Calculation (Post-Order Traversal of the Document Tree)
In the same step in calculating the term vector, the node size, i.e., the number of words are also determined. The size for a non-leaf node can be obtained by simply slimming up the sizes of the descendant leaf nodes.
Automatic Link Generation Based on the Link Profile
A link is created on a node in the document tree if and only if none of its children have links created. HieNet applies pre-order (top-down) tree traversal to create a link on a node that is as small as possible. Only when this attempt fails, then the link manager considers links on a larger section. This heuristic rule is employed because the user is most likely to be interested in reading links that connect sections containing the fewest words, such as a paragraphs in conducting a document search on the networked databases. In the case when a user desire to examine a larger body of text, a user option is provided by the use of slide bar for controlling the node size in establishing the links.
Dynamic Link Generation Based on User Controllable Parameters
HieNet provides two slider bars; one for the user to control the node similarity threshold and the other for controlling the node size. By default, HieNet generates links between a Fair of smallest nodes that satisfies both the similarity threshold and the node size. The node granularity can be flexibly changed with limitations for document search in establishing the links. For example, the auto-generated links can vary from paragraphs to chapters, books to sections, or vice versa.
HieNet checks if the current node has a similarity measure above the threshold. Only then does it traverse to the descendants of that node. Otherwise, it ignores the sub-tree of that node completely. It is not likely that any relevant information is down in that branch of the document since all the descendent nodes had already sent the term weight upward. For example, if a chapter level node still does not has a sufficient weight to pass the similarity test, then it will be futile to check for any of its descendent nodes. After a node passes the similarity test, it is checked to determine if it has a right size according to a user input requirement.
Because of the "tree pruning" heuristics, the time complexity for generating links is drastically lower than O(n). Thus the user is able to interactively change these parameters and obtain an instantaneous response of dynamically created links. The high degree of interactivity is what make this approach practical. The quality for the system generated links based on lexical co-occurrence is fundamentally limited by the range and consistency of words used by the documents. Users generally require some trial and error attempts to adjust the linking parameters to generate a reasonable link and to eliminate the irrelevant links. The link management system must provide a system that the user can interactively perform the link and search for the system to be practically useful.
An empirical test of HieNet is applied to two set of textual documents with very different content but with many specific terms in common. Specifically, seven articles related to the Los Angeles riots from Newsweek and Time Magazines in SGML format are intermingled with two chapters of an object oriented C++ graphic package manual. Words like color, model, value, and class have very high frequencies in both text bodies. The sample documents consist of about 16,000 words. FIG. 5 shows the words extracted by HieNet in processing the text. The system generated links by HieNet only links the articles related to either to the Los Angeles Riot or the O--O manuals but no links between them. FIG. 6F also shows that useful and meaning links are generated by HieNet As shown in FIG. 6F, the first link is a user generated link while the second and the third links are system generated links based on the user profile presented to HieNet through the user generated link. From the second and the third links, when compared to the first link, i.e., the user generated link, it is quite obvious that the user interest in discussing the timing and rapid-spreading of the Los Angeles riot are fully taken into consideration when HieNet is executed to provide the system generated links.
Although the present invention has been described in terms of the presently preferred embodiment, it is to be understood that such disclosure is not to be interpreted as limiting. Various alternations and modifications will no doubt become apparent to those ski/led in the art after reading the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alternations and modifications as fall within the true spirit and scope of the invention.
TABLE 1______________________________________Component No. Name and Functions Performed______________________________________100 Hypermedia link management system101 Link Generator-generates new hypermedia links automatically based on user created links102 Link manager - calculates a link profile per user created link & stores both user created and link generator created links103 Indexer-Creates index information for hypermedia docurnents104 Structure reader- decomposes hypermedia documents into objects and setup structure tree105 I/O controller-controls data input and output106 Hypermedia database-stores hypermedia documents107-109 Computers or workstations110 Remote hypermedia link management system on network200 Link generation controller-controls link generation201 Output port to Link manager- transfers user created link including the link profile to link manager202 Input port to PC- transfers system generated links to PCs203 Content input port-transfers content of hypermedia content to PC users204 Local area network-connects local PCs205 Internet system- connects multiple remote systems301 Data bus - transfers new documents to indexer302 Data-bus - connects user to Internet systems303 Data bus - sends data to structure reader304 Data bus - sends structured documents to Indexer305-306 Data bus -loads indexing data to link generator307 Data bus -sends links to link manager______________________________________ | 4y
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This application is a continuation-in-part of application No. 187,421 which will be abandoned upon filing of this application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a breath controlled switching device, for operating a multiswitched system such as a music synthesizer or other instrument for generating visual or sound information in response to signals.
2. Background to the Invention
In the field of musical instrument simulation many efforts have been made to electronically simulate the playing of orthodox instruments, wherein the operation of various means have been used to control electronic switching by means of which tone generators or other forms of music synthesizer are energized.
For example, in U.S. Pat. No. 3,516,326 issued June 23, 1970 to Hilliaret et al, discloses a harmonica in which air flow variations are sensed by piston and cylinder arrangements and motion of this mechanical transponder is directly transformed into electronic signals. The transponder is within the environment within the pipe and is necessarily operating in wet conditions under the influence of the breath and saliva of the operator. It may be difficult or impossible to prevent the condensation of moisture from the breath and /or the accumulation of saliva within the pipes. Nobel et al, in U.S. Pat. No. 3,767,833, discloses a somewhat similar system to that of Hilliaret, but Noble's device has only one pipe, different notes being achievable by keying. It would be desirable to devise a system in which there is no direct electrical connection to the transponder.
It is an object of the invention to provide a breath controlled device for providing signals to a generator of visual or information or music synthesizer, e.g. a harmonica, which may include a simple, low cost arrangement utilizing components that are insensitive to environmental hazards, such as the presence of saliva, and which are robust and long lives.
It is an additional object of the invention to provide other instruments, such as suck/blow operated typewriters or computer keyboards which are especially useful for the disabled.
SUMMARY OF THE INVENTION
In one embodiment the present invention provides a computer controlled device for producing signals for the operation of apparatus for producing sound or visual information in response to said signals, the device comprising; a mouth piece having a plurality of air pipes adapted for the selective passage of sucked and blown air from an operator, at least a portion of each air pipe comprising a light transmitting wall adapted to allow transmission of light through the pipe; light responsive means located on one side of the pipe adapted to receive light from the other side of the pipe through the light transmitting wall; actuating means within each pipe movable under the action of air displacement within the pipe from a first position in which it blocks the transmission of light through the pipe into a second position in which it allows transmission of light through the light transmitting wall, the actuating means being biased, in use, into its first position; and photo-sensitive signal generating means for each actuating means located in a path of transmitted light.
Preferably, light emitting means such as LEDs are provided on a side of each pipe opposed from the light responsive means, the light emitting means being adapted to illuminate said light transmitting wall.
In a further embodiment one or more pipes is provided with lip actuated shift controls. Thus, for example, in the case of a musical instrument, these additional switching means may be used to switch pitch ranges, eg. octaves, while the air blown switching function can simultaneously be maintained unimpeded.
When the generator of sound or visual information is a typewriter keyboard or a computer keyboard, using, for example, a row of twelve pipes in side-by-side arranged relation, the provision, for instance, of a two position mouth shift control mode gives two different ranges for each blow controlled signal or each suck controlled signal thereby providing a 48-character capability.
Each pipe may be arranged to be directionally responsive to both exhalation and inhalation air flow, by the provision of additional actuating means in each pipe. A pipe especially designed for "soft" blow and/or suck may have means to concentrate or direct the air flow to minimize air flow requirements for moving the actuating means.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention will now be described by way of example with reference to the drawings, in which:
FIG. 1 is a view of one device according to the invention;
FIG. 2 is a section through a pipe of the device shown in FIG. 1;
FIG. 3 is a front view of the device as shown in FIG. 1; and
FIG. 4 is a section through the mouthpiece of the device of FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENTS
The drawings show a breath controlled switching device 10 which is primarily intended for use in producing signals which apparatus may be used to operate a music synthesizer to function, for example as a harmonica. The device 10 is, however, suitable for producing signals to correspond with those of a typewriter or computer keyboard.
The device 10 comprises a plurality of pipes 12. Twelve pipes 12 are illustrated, but this number is not critical and is dependent on the number of different signals it is desired to send to the operated apparatus and on the number of shifts available different sets of operands of the operated apparatus.
Each pipe 12 as illustrated comprises a mouthpiece 14 allowing access of the breath of a user to an opening 16 of each pipe 12. The openings 16 may suitably be at the ends of pipes 12 as illustrated but other arrangements are possible.
Each pipe 12 contains at least one ball 18 which is movable in the pipe in response to the user blowing or sucking on the pipe. The object need not be ball 18 as illustrated, but may be any object which will move in the pipe in response to the users breath.
The or each ball 18 is contained in a chamber 20 of the pipe 12, the chamber 20 being formed by a portion 22 of the pipe wall which is able to transmit light therethrough and partition walls 24, 26 which allow the passage of gas current therethrough. For example, as illustrated the partition walls 24, 26 may have apertures 27 therethrough. Alternatively, partition walls 24, 26 may be mesh or other open structure.
The light transmitting wall portion 22 may suitably be clear plastics material and it is conventional that the whole pipe 12 be formed of this material for each of manufacture. However, for the purpose of emphasizing the presence of the light transmitting portion 22, the drawings indicate a change of material for the body of the pipe 12 and the light transmitting wall portion 22.
To one side of each pipe 12 adjacent a light transmitting wall portion 22 is a photo-sensitive switch 30, suitably photo transistor.
In use, the generally opaque ball 18 in chamber 20 occupies an at-rest position resting against partition 26. When there is air flow in the pipe 12 to displace ball 18 to the position shown in phantom light may pass through the transmitting wall portion 22 from one side of pipe 12 to the other. When this is so, photo-sensitive switch 30 will conduct and a signal will be produced. When ball 18 returns to its original position, light will be shut off and photo-sensitive switch 30 will not conduct and no signal will be present. While it is possible to use the device 10 so that the light transmitting portions 22 of pipes 12 opposed from the photo-sensitive switches 30 are illuminated by any convenient light source, it is convenient to provide a light source 28 for each pipe located opposed to photo-sensitive switch 30. Each light source 28 may be a light emitting diode LED.
Again for purposes of convenience, the photo-sensitive switch 30 and LED 28 need not abut light transmitting wall portion 22 but may be spaced therefrom by in line pipes 29, 31 which are also in line with the at-rest position of ball 18.
If ball 18 does not return to its at-rest position, photo-sensitive switch 30 will continue to conduct and the produced signal will be continuous. While this may be convenient for some purposes, it is generally not so and therefore means should be provided to return ball 18 to its at-rest position.
As illustrated, the return means are downwardly inclined portions 34 of the pipe 12 , and upwardly inclined portions 36 of the pipe 12. In portion 34, the at-rest position of ball 18 is resting on partition 26. When the user sucks on pipe 12, the ball will move upwardly to the position shown in phantom and the respective photo-sensitive switch 30 will conduct. When sucking stops, the ball falls back on partition 26, light is blocked from the photo-sensitive switch, and the switch does not conduct. During this operation any sucking action on the ball 18 in the upwardly inclined portion 36 rests on it respective partition 26 which prevents it from movement in the sucking direction.
When the user blows into pipe 12, the ball 18 in downwardly inclined portion 34 does not move due to it s respective partition 26 but ball in upwardly inclined portion 36 moves into the position shown in phantom and its respective photo-sensitive switch 30 conducts.
As shown, a forward portion of pipe 12 is shown as downwardly inclined and a rearward portion is shown as upwardly inclined. This juxtaposition may be reversed, or a straight pipe may be used to be fitted as desired by the user, or any other means of biasing the balls 18 or other movable object in the pipe may be used. Furthermore, it is not necessary to include actuating means movable by each of sucking and blowing in the same pipe. If desired, means actuating the photo-sensitive switch or blowing may be provided in one pipe and means actuating the photo-sensitive switch or blowing may be provided in another pipe. It may also be possible to provide two means in the same pipe 12 which actuate different photo-sensitive switches dependent on the strength of the blow.
When suck actuating means and blow actuating means are provided in the same pipe they may, if desired, be used to provide signals for the same operand, i.e. if the apparatus to be operated is a music synthesizer, suck and blow on the same pipe may each produce the same note. This is easily achieved by connecting the photo-sensitive switches 30 for both balls 18 of a pipe 12 in parallel. Resistors may be included in such circuit, for example, as heaters for the pipe and/or as ballasting resistors for the photo-transistors 30. However, it may be more usual for sucking and blowing to operate different functions of the operated apparatus. Thus, for twelve pipes, twenty-four alternative functions may be operated. For many purposes twenty-four operands are insufficient. A harmonica, for example, may use more than twenty-four notes and sharps and flats should be provided. For keyboard simulation, at least an upper and a lower case alphabet set, numbers and punctuation marks are required.
The number of signals which may be sent may be increased by increasing the number of pipes 12 in device 10. However, the device may become unweldy if the number of pipes is increased beyond a convenient maximum. Shift switches may be provided to shift the signals from the photo-sensitive switches to different ranges. These shift switches may be provided by any convenient means. For example, a manual switch may be provided a switching mechanisms associated with one or more pipes 12 may be utilized for the purpose.
According to a feature of the invention, however, a shift switch or switches may be provided to be actuated by movement of upper lip bar 42 or lower lip bar 44. Each or both of these may be moved in three directions. Thus, upper lip bar 42 may be moved by the upper lip of the user in the direction of arrow A of FIG. 3 to operate shift switch 46, or it may be moved in the direction of arrow B of FIG. 3 to operate shift switch 48 or it may be moved in the direction of arrow C in FIG. 4 to operate shift switch 50. Similar operation of lower lip bar 44 is possible. Thus independent operation of lip bars 44 may provide at least as many as six shifts to different ranges of functions. However, if provision is made different shifts for combinations of positions of lip bars 42, 44, then the number of shifted ranges is greater than six.
Lip bars 42, 44 have a rear slide member 43 running in a slot in a housing 45. Each bar 42, 44 may be moved in the direction of arrows A or B with slide 43 moving longitudinally in the slot. Additionally, each bar 42, 44 may be pushed rearwardly in the direction of arrow C.
Additionally, further switches 53, 55 may be operated by depressing additional lip bars 52, 54. Lip bars 52, 54 do not operate in the same manner as lip bars 42, 44, but are each formed by a resiliently bent over portion of the mouthpiece. If the bars 52, 54 are to be used independently of each other, they are each conveniently used in conjunction with the other of the lip bars 44, 42. Thus upper lip bar 52 is conveniently used with lower lip bar 44, and lower lip bar 54 is conveniently used with upper lip bar 44. When neither of the lip bars 42, 42 is used with lip bars 52, 54 there may be a tendency to depress both of them together.
Because either of lip bars 52, 54 is easily operated in any of the positions of the lip bars 42, 44, these lip bars 52, 54 are, when the apparatus to be operated is a music synthesizer, conveniently used to produce sharps and flats of notes. Of course, any of switches 46, 48, 50 or the corresponding switches 53, 55 for lower lip bar 44 may be used for sharps or flats. However, since switches 46 and 48 can not be operated at the same time since different locations of lip bar 42 are required, it may be convenient to utilize one of switches 46 or 48 to produce sharps and the other to produce flats. The actual manner of producing the sharp and flat notes may be conventional. It is only important that the actuating means to charge the note by half a tone upwardly or downwardly be applicable to all the shifted ranges of notes. | 4y
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This application is a continuation application and claims priority under 35 U.S.C. Section 120 of U.S. application Ser. No. 09/205,418, filed Dec. 2, 1998, issued as U.S. Pat. No. 6,163,859, on Dec. 19, 2000. The disclosure of the prior application is considered part of and is incorporated by reference in the disclosure of this application.
BACKGROUND
Inexorable advances in electronics have led to widespread deployment of inexpensive, yet powerful computers that are networked together. Over time, programs installed on these computers are updated and these updates need to be maintained. Information system departments and their users face the thorny task of maintaining numerous instances of software across their complex distributed environments. The maintenance process covers a number of tasks, including software installation, synchronization, backup, recovery, analysis and repair.
A detailed knowledge of a computer's dynamic environment and its system configuration is needed in the maintenance process to prevent situations where modifications to one component may introduce problems in other components. Moreover, an accurate knowledge of the system's configuration is required to verify compatibility and to ensure integrity across multiple operating environments and across diverse processors. Software applications can have numerous components and dependencies and, in a modern network with diverse processors and peripherals, the range of possible configurations can be staggering.
Historically, relationships between software components have been manually detected and component states have been recorded in a log. This state information is external of the components themselves and must be updated whenever the components change. As state information is recorded only at the time of installation, changes made subsequent to installation may be lost. As the rate of change increases and complexity of the software configuration grows, the external state representation becomes difficult to maintain and prone to error. Moreover, during normal operation, users may make changes to the software through individual personalization and through the installation of additional software, thus changing the state information. The difference in state information between software installation and software operation can lead to unpredictable behavior and may require support from information system personnel.
SUMMARY OF THE INVENTION
In one aspect, a computer-implemented vault archives software components, where only a single instance of each component that is multiply-used is stored in the vault. The vault includes unique instances of the one or more software components and an access controller for performing a direct, random access retrieval of the one or more software components from the vault.
Implementations of the invention include one or more of the following. The access controller generates a unique key. The unique key may be used to access a software component. The unique key may be generated from a persistent metadata description. A post controller may perform a direct, random access insertion of a software component to the vault. The post controller may generate a unique key from the new component and optimizes storage if the unique key exists. A look-up controller may perform a direct, random access determination of the existence of a software component in the vault. A client may be coupled to the vault, the client having a physical software component residing on the client, the client generating a key from the physical software component. One or more secondary vaults may be coupled to the vault with a fault-tolerant rollover system for sequentially searching each vault for the presence of a target software component. The secondary vaults may be ordered based on accessibility of the vaults. A client may generate a key and apply the key to recover the target software component from the most accessible of the vaults. The client may use a metadata description to generate the key. If the search of a determined vault fails to locate the target software component, the client may skip the determined vault and modify the search order of the vaults in recovering the target software component.
In a second aspect, a computer-implemented vault archives software components, where only a single instance of each component that is multiply-used is stored in the vault. The vault includes means for storing unique instances of the one or more software components on the vault; and access means for performing a direct, random access retrieval of the one or more software components from the vault.
Implementations of the invention include one or more of the following. The access means may generate a unique key. The unique key may be used to access a software component. The unique key may be generated from a persistent metadata description. A post means may perform a direct, random access insertion of a software component to the vault. The post means may generate a unique key from the new component and optimize storage if the unique key exists. A look-up means may perform a direct, random access determination of the existence of a software component in the vault. A client may be coupled to the vault, the client having a physical software component residing on the client, the client generating a key from the physical software component. One or more secondary vaults may be coupled to the vault with means for sequentially searching each vault for the presence of a target software component. The secondary vaults may be ordered based on accessibility of the vaults. The client may have a means for applying the key to recover the target software component from the most accessible of the vaults. The client may use a metadata description to generate the key. If the search of a determined vault fails to locate the target software component, the client may skip the determined vault and modifies the search order of the vaults in recovering the target software component.
In a third aspect, a method for archiving software components where only a single instance of each component that is multiply-used is stored in a vault includes: storing unique instances of the one or more software components in the vault; and performing a direct, random access retrieval of the one or more software components from the vault.
Implementations of the invention include one or more of the following. The method may generate a unique key. The unique key may be used to access a software component. The unique key may be generated from a persistent metadata description. The method may perform a direct, random access insertion of a software component to the vault. A unique key may be generated from the new component and used to optimize storage if the unique key exists. The method may perform a direct, random access determination of the existence of a software component in the vault. A client may be coupled to the vault, the client having a physical software component residing on the client, the client generating a key from the physical software component. One or more secondary vaults may be coupled to the vault and sequentially searched for the presence of a target software component. The secondary vaults may be ordered based on accessibility of the vaults. The client may apply the key to recover the target software component from the most accessible of the vaults. The client may use a metadata description to generate the key. If the search of a determined vault fails to locate the target software component, the client may skip the determined vault and modifies the search order of the vaults in recovering the target software component.
Advantages of the invention include one or more of the following. The vault can inventory, install, deploy, maintain, repair and optimize software across local and wide area networks (LANs and WANs). By automating the human-intensive process of managing software throughout its life cycle, the vault reduces the total cost of ownership of computers in networked environments. Users can reduce the time required for software packaging by simply probing an application for its current state and storing unique instances of components of the software in a vault. Software installation may then be performed by moving valid working states from one client machine to another. Further, error prone installation of the software is avoided, increasing the out-of-box success by installing known working software states and insuring against deletion of shared components.
Moreover, the vault can be used to diagnose problems by comparing an existing state on a client computer to both a previously working state and a reference state stored in the vault. Further, the vault can be used to allow applications which have been damaged to self-heal applications by automatically restoring previously working states or reinstalling components from reference states.
The vault can also support remote and disconnected users by protecting applications on their desktop and ensuring that software is configured appropriately. The vault can also synchronize user desktops by automatically updating all application components and configuration settings while still allowing custom settings for the user. The vault also automates custom computer setups/upgrades by providing replication of working states from client machines. Information stored in the vault may be used to provide vital application information including system values and resource conflicts to help information systems personnel.
Further, the vault decreases network overhead and increases scalability of electronic software distribution by eliminating delivery of duplicate files that make up software packages. The flexible architecture of the invention protects user investment in existing solutions for enterprise-wide systems management, network management, and application management.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating a system with one or more vaults for communicating with one or more clients.
FIG. 2 is a diagram illustrating communications between the client and the one or more vaults.
FIG. 3 is a flowchart illustrating a process for accessing software components from the vault.
FIG. 4 is a flowchart illustrating a process for comparing keys in FIG. 3 .
FIG. 5 is a flowchart illustrating a process for posting software components to the vault.
FIG. 6 is a flowchart illustrating in more detail the process for generating a post key in FIG. 5 .
FIG. 7 is a flowchart illustrating a process for performing lookup based on an identity key.
FIGS. 8A and 8B are flowcharts illustrating alternative processes for software management.
FIG. 9 is a flowchart illustrating a process for publishing meta data information associated with the software components.
FIG. 10 is a flowchart illustrating a process for storing software components on the vault.
FIG. 11 is a flowchart illustrating a process for replicating software components from the vault.
FIG. 12 is a flowchart illustrating an exemplary application of the vault in installing software.
FIG. 13 is a diagram of an exemplary application for maintaining software using the vault.
DESCRIPTION
FIG. 1 shows a computer system 100 with one or more vaults. The system 100 has one or more clients 102 , each of which has a set of catalogs 104 , as well as a client vault 106 . The client vault 106 is a computer readable medium which stores one or more software components (entities) which are designated by the set of catalogs 104 . In this case, the client vault 106 exists on a data storage device such as a hard drive on the computer system 100 . Alternatively, the vault may reside on one or more data storage devices connected to a network 110 , as discussed below. Each of the software components may be referenced by more than one application, and the software components are used to reconstruct the application.
Each catalog 104 includes metadata which is generated by determining run-time states of each software application. Generally, the metadata for each software application is an abstract representation of a predetermined set of functionalities tailored for a particular user during installation or customized during operation of the software application. The metadata is a list pointing to various software components (entities) making up an application software and a root entity which represents an action that may be performed by the user at another machine, place or time.
The metadata is generated by analyzing the run-time states of the software application and checking the existence of the entities and entity dependencies, which may change over time. The list of the entities is pruned by deleting overlapping entities and by combining similar entities. In the grouping of entities in the metadata, an intersection of the entities is determined such that a package of entities can be succinctly defined and that all the information necessary for it can be represented as the metadata with or without the actual entities. Enough information about each entity is included in the metadata so that an analysis of correctness may be performed. The resulting metadata provides indices to the client vault 106 , which stores unique instances of software components locally to the client 102 .
In addition to the client vault 106 , the client 102 may also access remotely stored component files associated with the catalog 104 . To access these remote component files, the client 102 communicates over the network 110 , which may be an intranet, or a wide area network (WAN) such as the Internet. The network 110 may also be a local area network (LAN). Connected to the network 110 are one or more vaults 112 , 114 and 116 . Each of the vaults 112 – 116 includes sets of catalogs 118 – 120 which are indices of metadata files that represent the physical components of the software being “published” for the client 102 .
FIG. 2 shows in more detail various communication modules between a client 122 and one or more vaults 130 – 132 . The vaults 130 – 132 may be local vaults, remote vaults accessible from a network, or a combination of both. In FIG. 2 , an access controller 124 allows the client 122 to retrieve files from the one or more vaults 130 – 132 . A post controller 126 allows the client 122 to place one or more files on the vaults 130 – 132 . A lookup controller 128 allows the client 122 to preview and compare catalogs of files stored locally versus files stored on the vaults 130 – 132 . Each of controllers 124 , 126 and 128 may be implemented using a processor on the client 122 and computer instructions as described below. Alternatively, each of controllers 124 , 126 and 128 may be implemented using a processor 15 ′ which is located on the network 110 . Pseudo-code showing file accesses using the access controller 124 , the post controller 126 and the lookup controller 128 is as follows:
//**** Access Controller Pass metadata descriptor Transform metadata descriptor into key for each vault
directly access key on vault if found then end for
next return full URL and file for key //**** Post Controller Pass metadata descriptor Transform metadata descriptor into key for each vault
directly access key on vault if found then end for
next if not found then
locate first writable vault insert file with key
end if return //**** Lookup Controller Pass metadata descriptor Transform metadata descriptor into key for each vault
directly access key on vault if found then return full URL
next return not found
Turning now to FIG. 3 , a process 140 for accessing files stored on one of the vaults 130 – 132 is shown. The process 140 first generates a key from a metadata file (step 142 ). The metadata file identifies all elements that make up a single application, as identified using a state probe. The operation of the state probe is described in more detail in U.S. Pat. No. 5,996,073, entitled “System and Method for Determining Computer Application State,” issued on Nov. 30, 1999, the content of which is incorporated by reference.
The metadata file describes the elements of the application, including the location of the files and the configuration of the application. The size of the metadata file is typically a small fraction of the size of the total state referenced. The key from the metadata file may be used to access and retrieve component files stored in the vaults 130 – 132 .
If the component files of the application software to be recreated using the key are large and therefore cumbersome to transfer, it is more efficient to determine whether the component files of the application software already exist locally. Such determination may be made by first looking up the key on the client 122 (step 144 ) and then optionally comparing the key generated from the metadata file to the key on the client 122 (step 146 ) and is described in reference to FIG. 4 . The key comparison process sets a flag if a difference exists and otherwise clears the flags.
The difference flag is then checked (step 148 ). If the difference flag is set, the key generated from the metadata file is used to retrieve software components files from the vault (step 150 ). Alternatively, if the flag is cleared, the desired file already exists on the client 122 and the process 140 exits (step 152 ). Pseudo-code for the process 140 is as follows:
Transform metadata descriptor into key Using location attributes of key, locate file on client Generate key for local file compare metadata key and local key if metadata key matches local key then return for each vault
directly access key on vault if found then retrieve file
next return success if found
Turning now to FIG. 4 , the key comparison step 146 of FIG. 3 is illustrated in more detail. First, the difference flag is initialized to zero (step 160 ). Next, the process 146 determines whether binary data associated with the files being compared are different (step 162 ). If no difference exists, the process exits (step 176 ). Alternatively, if the binary data differ, the process then compares the keys based on various sequence attributes associated with each of the files being compared (step. 164 ).
For example, location attributes, defined as directory paths, may be checked. Once the location attributes are determined to be equal, the sequence attributes may be used for further identification. A combination of multiple sequence attributes may be used together to reliably determine identity. Common examples of sequence attributes may include, but are not limited to, attributes such as date created, date modified, date last accessed, and version number. Certain sequence attributes may take precedence over other sequence attributes. For example, if the version numbers are not equal, date attributes may be ignored.
The process of FIG. 4 checks whether the sequence attributes are equal (step 166 ). If so, the difference flag is set (step 168 ). From step 166 , if the attributes are not equal, the process checks whether one of the attributes is newer than the other (step 170 ). If so, the process proceeds to step 168 to set the difference flag. Alternatively, in the event that the attribute is not newer, the process then checks whether or not one of the attributes is older (step 172 ). If no, the process proceeds to step 168 to set the difference flag. Alternatively, in the event that one of the attributes is older, the process determines whether or not the file may be overwritten (step 174 ). If so, the difference flag is set (step 168 ). Alternatively, the process exits (step 176 ).
Referring now to FIG. 5 , a flowchart illustrating a post-process 180 for placing files onto the vault is shown. The post-process 180 first generates a post key from the metadata file (step 182 ). Optionally, the process 180 may look up the key present on the vault (step 184 ) and compare the keys (step 186 ). If the comparison causes the difference flag to be set (step 188 ), the key from the metadata is used to post the file to the vault from the client (step 190 ). From step 188 or step 190 , the process of FIG. 5 exits (step 191 ). Pseudo-code for the process 180 is as follows:
Transform metadata descriptor into key for each vault
directly access key on vault if found then end for
next if not found then
locate first writable vault insert file with key
end if return
Turning now to FIG. 6 , the process 182 of FIG. 5 to generate the post key from the metadata file is shown in more detail. In FIG. 6 , metadata associated with each file is generated (step 183 ). Next, the process 182 verifies the integrity of the file (step 185 ).
Integrity is verified using a sufficiently unique byte level check to statistically guarantee that the file is intact. Various known algorithms may be used, including 32-bit checksums, cyclic redundancy checks, and hash-based functions and checksums. While any method which detects a change in the byte ordering of the file may be used, a method with high levels of statistical uniqueness and favorable performance characteristics should be used. For example, MD5 (Ron Rivest, 1992) provides a cryptographically strong checksum.
A key is then generated from the metadata (step 187 ) before the process 182 exits (step 189 ). Key generation should include an integrity checksum as described above as well as basic information about the size, name, and attributes of the file. In the form of a checksum, the key allows identity information as well as integrity information to be easily verified.
Turning now to FIG. 7 , a process 190 for performing look-ups based on an identity key is shown. The process 190 first enumerates all available vaults in a vault chain (step 192 ). Next, for each vault, the process 190 generates a universal resource locator (URL) based on the vault and the identity key (step 194 ). Next, the process 190 checks for the existence of the URL (step 196 ). If the URL exists in step 198 , the vault has been located and the process 190 exits (step 202 ).
The URL specifies a unique address using one or more protocols to identify and access local and remote resources. Alternatively, if the current vault fails to offer the correct URL, the next vault is selected (step 200 ) before the process 190 loops back to step 194 to continue searching all vaults in the vault chain. If all vaults have been searched but the URL is not found, the process returns with an error indication. Pseudo-code for the process 190 is as follows:
Transform metadata descriptor into identity key Construct redundant vault chain Sort vault chain in order of closest accessibility for each vault
form URL based on vault location and identity key check existence of URL if found then return vault location and URL
next if not found then return error
FIGS. 8A and 8B show alternative processes to provide state-based software life cycle management using a vault. Turning now to FIG. 8A , a process for performing software management first generates the metadata (step 403 ), as described in FIG. 1 . The metadata may include DNA information, as described in more detail in the incorporated-by-reference application. The information is then used to maintain software (step 405 ) before the process exits. Correspondingly, FIG. 8B shows a second software life cycle management process. Initially, the metadata information is generated and published (step 410 ). Next, components of the software are replicated (step 450 ) based on the metadata. The software is then installed (step 470 ). After installation, the software may be maintained (step 490 ).
Turning now to FIG. 9 , the metadata publication step 410 is shown in more detail. In FIG. 9 , a vault is located (step 412 ). The vault may be a server that maintains items referenced in the metadata files. Next, component files associated with the software are stored in the vault (step 414 ). Similarly, metadata is stored in the vault (step 416 ). A catalog, or an index of metadata files that represent the physical components of the software being published, is updated (step 418 ). Finally, the process 410 exits (step 420 ).
Turning now to FIG. 10 , the file storing step 414 of FIG. 9 is shown in more detail. Each item in the metadata file is initially selected (step 432 ). The integrity of the item is verified (step 434 ). The metadata information is used to verify the integrity of the item. Simple sequence and identity attributes are compared to ensure that no change has occurred to the file. The fastest comparisons are performed first with slower but more reliable checks being performed later. By using a combination of attributes which may include the date accessed, date modified, version number, date created, multiple file checksums, block checksums, complete byte comparisons, secure file hashing, and file attribute comparison, the integrity of the file may be reliably correlated to the information in the metadata.
The replicate step 450 of FIG. 8B is shown in more detail in FIG. 11 . First, the source vault is located (step 452 ). Next, the destination vault is located (step 454 ). Files are then transferred from the source vault to the destination vault (step 456 ). Similarly, metadata information is copied from the source vault to the destination vault (step 458 ). Finally, the vault catalog is updated (step 460 ) before the process of FIG. 11 exits (step 462 ).
Turning now to FIG. 12 , the installation step 470 ( FIG. 8B ) is shown in more detail in FIG. 12 . First, the vault catalog is loaded (step 472 ). Next, the highest version of the software stored in the vault is determined (step 474 ). The metadata associated with the highest version of the software is copied to the target machine (step 476 ). Further, data is remapped (step 478 ). The process of FIG. 12 then applies a preprocessing operation to the remapped data (step 480 ) to convert data into the proper format and set up variables appropriately, among others. Further, items associated with the software are installed (step 482 ). A post-processing process is applied (step 484 ). This step is similar to step 480 in that variables are checked and data is formatted. Finally, an inventory of the software being installed is updated (step 486 ) before the process exits (step 488 ).
Turning now to FIG. 13 , the maintenance step 490 of FIG. 8B is shown in detail. The maintenance step 490 is an event driven process and thus receives a software trigger event (step 492 ). Based on the trigger event, the process of FIG. 13 determines various possible events, including a check for update event 494 , a protect software event (step 496 ), a software recovery (step 498 ) event, a check removal event (step 500 ), and an examine system event (step 502 ). From steps 494 – 502 , the triggering event is reported (step 504 ) before the process of FIG. 13 exits (step 506 ).
In the manner discussed above, the vault can inventory, install, deploy, maintain, repair and optimize software across LANs and WANs. The vault installs only known working software combinations and insures against deletion of shared components, thus protecting user investments in existing solutions for enterprise-wide systems management, network management, and application management.
The techniques described here may be implemented in hardware or software, or a combination of the two. Preferably, the techniques are implemented in computer programs executing on programmable computers that each includes a processor, a storage medium readable by the processor (including volatile and nonvolatile memory and/or storage elements), and suitable input and output devices. Program code is applied to data entered using an input device to perform the functions described and to generate output information. The output information is applied to one or more output devices.
Each program is preferably implemented in a high level procedural or object-oriented programming language to communicate with a computer system. However, the programs can be implemented in assembly or machine language, if desired. In any case, the language may be a compiled or interpreted language.
Each such computer program is preferably stored on a storage medium or device (e.g., CD-ROM, hard disk or magnetic diskette) that is readable by a general or special purpose programmable computer for configuring and operating the computer when the storage medium or device is read by the computer to perform the procedures described. The system also may be implemented as a computer-readable storage medium, configured with a computer program, where the storage medium so configured causes a computer to operate in a specific and predefined manner.
While the invention has been shown and described with reference to an embodiment thereof, those skilled in the art will understand that the above and other changes in form and detail may be made without departing from the spirit and scope of the following claims. | 4y
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BACKGROUND OF THE INVENTION
This invention relates generally to devices for handling semiconductor wafers without contaminating or damaging the wafers, and more particularly to a device for transporting semiconductor wafers to and from a susceptor.
The production of high quality semiconductor wafers requires the maintenance of damage free wafer surfaces. Handling of the wafers gives rise to the opportunity for damage or contamination. For example, damage or contamination frequently occurs during transfer of a wafer to a susceptor which is used for the deposition of an epitaxial layer on a front face of the wafer. The susceptor is a generally polygonal, vertically oriented tube made of silicon carbide coated graphite. Outer surfaces of the walls of the tube have circular recesses in them, each recess being sized to hold one wafer with the front face of the wafer directed outwardly from the susceptor. The susceptor holds multiple wafers in a reaction chamber during the epitaxial layer deposition process. Rear faces of the wafers generally engage the back of the recesses so that a minimum amount of material is deposited on the rear face.
Typically, wafers are transferred from a storage cassette to the susceptor recess by special tweezers (tongs) or a vacuum wand. The tongs engage the wafer on both the front and rear faces along peripheral edge margins of the front and rear faces. A vacuum wand engages a central portion of the rear face of the wafer. The wand cannot engage the front face of the wafer inwardly of its peripheral edge margin or contamination may occur. Engagement with the peripheral edge margin of the front face does not allow the wand to grip the wafer securely enough to pick it up.
The use of tongs or a vacuum wand requires the operator to insert the wafer into the wafer recess in a non-parallel fashion relative to the susceptor to provide a space between the back wall of the recess and the tong or wand engaging the rear face of the wafer. In either case, the wafer contacts the susceptor first at the bottom of the recess with the top of the wafer angling upwardly away from the recess. The top of the wafer is then frequently pushed into the recess with a separate pointed tool or tongs to seat the wafer in the recess. This often results in damage to the wafer by the tool or tongs. This loading and subsequent seating process also increases the chance of scraping the wafer against the sides of the recess during the manipulation of the wafer into the recess, resulting in damage to the wafer. Particulate contamination of the reactor and the wafer itself may result from even a small amount of scraping. These techniques occasionally result in the wafer not being securely placed against the susceptor resulting in thermally induced slip or the wafer falling off of the susceptor during processing.
The use of tongs or a vacuum wand also made it difficult to orient the wafer in a consistent manner in the susceptor recess, resulting in deposited silicon from previous reactor runs being underneath the wafer thereby preventing contact of the rear face of the wafer with the back wall of the recess. Moreover, the tongs used to carry the wafers rely solely on a frictional engagement with the faces of the wafer to grip the wafer. Thus, there are significant occurrences of wafers slipping out of the tongs and being damaged. The use of tongs or vacuum wand also requires the operator to have a high degree of manual dexterity to place the wafer in the susceptor recess without dropping the wafer or scraping it against the sides of the recess.
SUMMARY OF THE INVENTION
Among the several objects of this invention may be noted the provision of a device which provides for transfer of a semiconductor wafer to and from a susceptor without damage to the wafer; the provision of such a device which holds the wafer securely; the provision of such a device which can perpendicularly place the wafer in the susceptor while engaging only one face of the wafer; the provision of such a device which provides for consistent orientation of the semiconductor wafers on the susceptor; the provision of such a device which holds onto the wafer in such a way as to minimize the opportunity for contamination of the wafer by engagement with the device; and the provision of such a device which is easy to use.
A device of this invention is for use in handling a semiconductor wafer from a front face of the wafer on which a finished surface is formed by processing of the semiconductor wafer. The front face includes an outer peripheral edge margin. Generally, the device comprises fingers having tip portions adapted to engage the wafer for use in holding the wafer, and a frame mounting the fingers and positively locating the fingers for simultaneously engaging the wafer on the outer peripheral edge margin of the front face of the wafer while being free of engagement with a rear face of the wafer. Vacuum pressure passaging means terminates at the tip portions of the fingers for applying a vacuum pressure through the finger tip portions to the wafer to grip the wafer.
Other objects and features of the present invention will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a device for use in handling a semiconductor wafer shown holding a semiconductor wafer;
FIG. 2 is a front elevation of the device of FIG. 1 holding a semiconductor wafer; and
FIG. 3 is an enlarged fragmentary portion of the device of FIG. 1 showing the engagement of a finger tip portion of the device with the semiconductor wafer.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and first to FIG. 1, a device for use in handling a semiconductor wafer W of the present invention is generally indicated at 10. The semiconductor wafer generally indicated at W includes a front face FF on which a finished surface is to be formed by processing of the semiconductor wafer, and a rear face RF which may or may not be finished. The front face FF of the wafer includes an outer peripheral edge margin M which is not used in the finished wafer. The edge margin is approximately 3 mm wide on a wafer having a diameter of 150 mm, for example. Thus, the outer peripheral edge margin M does not have to remain defect free during the handling of the wafer W. The wafer W is generally circular in shape and has a flat F formed therein along a portion of the outer peripheral edge margin.
The device 10 is operable to perpendicularly place the wafer W into a wafer recess in a susceptor (not shown) for processing in an epitaxial reaction chamber (not shown) in a suitable manner such as described in coassigned U.S. Pat. No. 5,518,549, the disclosure of which is incorporated herein by reference. It is to be understood that although the present invention has particular application to the handling of semiconductor wafers W in the context of epitaxial layer deposition, it may be used for handling other items in other applications and still fall within the scope of the present invention. The wafer recess is generally circular and lies in an upright wall of the susceptor in which the wafer W is supported on a thin lip of the recess. More particularly, the wafer W engages the lip generally along the edge of the wafer. As disposed in the wafer recess, the front face FF of the wafer W is directed outwardly of the recess. An epitaxial layer is formed on the front face FF by the deposition of semiconductor material from a chemical vapor which is circulated through the reaction chamber and over the susceptor.
The device 10 includes fingers 22, a frame (indicated generally at 24) mounting the fingers and vacuum pressure passaging means (generally indicated at 23) for applying a vacuum pressure through tip portions 25 of the fingers to the wafer W to grip the wafer. The frame 24 includes a handle 26 extending perpendicularly from the front face FF of the semiconductor wafer W held by the device 10, and a manifold portion 28 defining a frame passageway therein. The frame passageway is in fluid communication with a finger passageway 30 of each finger 22. The handle 26 and frame passageway provide a fluid passageway for the vacuum pressure to be transmitted to the fingers 22 mounted on the manifold portion 28. The manifold portion 28 is made up of a plurality of tubular members. Six tubular members 32 form a structure in the shape of a pentagon (see FIG. 2) lying in a plane generally parallel to the front face FF of the semiconductor wafer W held by the device 10.
As shown in FIG. 2 the frame 24 has a center C generally coaxial with the center of the semiconductor wafer W when the wafer is held by the device. The fingers 22 are constructed and arranged for gripping the wafer W only at its peripheral outer edge margin M, thereby eliminating contact of the fingers with the portion of the wafer which will be used after processing. The manifold portion 28 is arranged such that the two fingers 22 extending from lower corners of the pentagon (as seen in FIG. 2) are located a distance r from the center C of the frame and the third finger extending from the uppermost corner of the pentagon is located a distance less than r from the center C. Generally, the distance r corresponds to (but is slightly larger than) the radius of the wafer W. The distance of the third finger 22 from the center C of the frame 24 corresponds to the shortest distance between the center of the wafer and the flat F. This arrangement permits the wafer W to be securely held by the device 10 in only one position with the third finger 22 engaging the flat portion F of the outer peripheral edge margin M. This allows the wafer W to be placed in the susceptor with the wafer flat F oriented in the susceptor pocket the same way (e.g., at the top of the recess) as preceding and subsequent wafers. The frame 24 is configured such that the fingers 22 extending from the corners of the frame are spaced apart for engaging only the outer peripheral edge margin M of the front face FF of the wafer W. Different size devices are required for different diameter wafers. It is to be understood that various other frame shapes may be used and a different number of fingers may be connected to the frame without departing from the scope of this invention.
The frame 24 includes a seventh tubular member 44 connected to the manifold portion 28 and lying in the same plane as the manifold portion. The seventh tubular member 44 extends from the bottom of the manifold portion 28 to generally the center C of the frame. The handle 26 is connected to the seventh tubular member 44 and extends perpendicularly from the manifold portion 28. In the illustrated embodiment, the handle 26 is taken from a vacuum wand such as one available from H-Square Company, of Sunnyvale, Calif., under model designation number NOP191 or NCP191. For example, the dimensions of the handle shown in FIG. 1 are 0.62" in diameter and 6.2" in length. The handle 26 includes a tip 45 attached to the frame 24 and a barbed connector 46 capable of attachment to a source of vacuum pressure (not shown). The handle 26 may be formed from a polymeric material or other suitable material. The handle 26 further includes a valve 48 for selectively opening and closing the passageway in the handle to control the application of vacuum pressure through the finger tip portions 25. Thus, the pressure may be controlled at the device 10 instead of at a remotely located vacuum pressure source. The valve includes a button 49 and a stem 51 for positioning a gate or ball type valve, or other suitable type of shut off device within the handle.
The tubular members 32 are formed from 0.25" stainless steel tubing. The tubular members 32 are connected with stainless steel elbows 58 and a tee 60. Other suitable material, such as plastic, may be used and different tubing sizes may also be used. It is envisioned that a frame (not shown) could also be made from solid bars formed in a configuration similar to the frame shown in FIGS. 1 and 2 and flexible tubing extending along the solid bars to provide a fluid passageway external to the rigid bars.
Each of the finger tip portions 25 has a notch 50 constructed for receiving a portion of the outer edge margin M of the wafer W therein for gripping the wafer, as shown for one of the fingers 22 in FIG. 3. The notch 50 defines a generally axially facing surface 52 and a projecting member 54 extending axially outwardly from the axially facing surface. The projecting members 54 of the lower two fingers 22 underlie and support the wafer to assist in holding the wafer along with the vacuum pressure. Generally, the distance r is measured from the center of the frame to a radially inward facing portion of the projecting member. A finger passageway opening 31 is located in the axially facing surface 52. The tip portion further comprises an axially rearwardly raked surface 56 sloping away from the axially facing surface 52. The finger tip portions are preferably made of a heat resistant plastic, such as plastic sold under the tradename VESPEL by E.I. DuPont de Nemours and Company.
In operation, the wafer handling device 10 is grasped in one hand by the handle 26 and the operator opens the valve 48 by pressing the button 49 to allow vacuum pressure to flow to the tip portions 25. The device 10 is then placed in contact with a wafer W with the projecting members 54 adjacent the outer peripheral edge of the wafer. The finger 22 extending from the upper corner of the manifold portion 28 is placed on the flat portion F of the wafer W. The vacuum pressure along with the projecting members 54 hold the wafer in a fixed position on the wafer handling device. The wafer W is then perpendicularly transported to the susceptor, properly aligned with the recess and placed securely in the recess. The operator then releases the button 49 of the valve 48 to shut off the flow of vacuum pressure to the finger tip portions 25 and release the wafer. The device 10 may also be used in transferring wafers to or from other processing equipment. A vacuum wand (not shown) may be used to transfer a wafer from a cassette to the wafer handling device.
It will be observed from the foregoing that the wafer handling device of this invention has numerous advantages. The illustrated configuration allows a semiconductor wafer to be picked up and held with vacuum pressure while only contacting the outer periphery edge margin of the wafer, thus reducing the possibility of damaging the front face of the wafer. The device allows the wafer to be placed on an epitaxial reactor susceptor from a perpendicular approach with respect to the device, thus providing better alignment on the susceptor than achieved by placing the wafer in the recess at an angle, and preventing damage to the wafer. Moreover, the device allows the wafers to be consistently positioned in the pocket in a selected orientation, further improving the quality of the finished wafer.
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
As various changes could be made in the above constructions and methods 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 shall be interpreted as illustrative and not in a limiting sense. | 4y
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This application is a divisional application of U.S. patent application Ser. No. 09/110,179 filed Jul. 6, 1998, now U.S. Pat. No. 6,137,334, the entirety of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to circuitry for generation of periodic signals such as dock signals. More specifically, the present invention relates to a delay line circuit for register controlled digital delay locked loop (DDLL) circuits which use fewer gates and have improved performance.
2. Description of the Related Art
Many high speed electronic systems possess critical timing requirements which dictate the need to generate a periodic clock wave form that possesses a precise time relationship with respect to some reference signal. The improved performance of computing integrated circuits (ICs) and the growing trend to include several computing devices on the same board present a challenge with respect to synchronizing the time frames of all the components.
While the operation of all components in the system should be highly synchronized, i.e., the maximum skew or difference in time between the significant edges of the internally generated clocks of all the components should be minute, it is not enough to feed the reference clock of the system to all the components. This is because different chips may have different manufacturing parameters which, when taken together with additional factors such as ambient temperature, voltage, and processing variations, may lead to large differences in the phases of the respective chip generated clocks.
Conventionally, synchronization is achieved by using DDLL circuits to detect the phase difference between clock signals of the same frequency and produce a digital signal related to the phase difference. By feeding back the phase difference-related signal to control a delay line, the timing of one clock signal is advanced or delayed until its rising edge is coincident with the rising edge of a second clock signal.
The operation of conventional DDLLs is shown in FIGS. 1 and 2. In FIG. 1, clock input buffer 104 , delay lines 101 , 102 , and data output buffer 109 constitute an internal clock path. Delay line 101 is a variable delay generator with a logic-gate chain. A second delay line 102 is connected to replica circuits 108 , which emulate the internal clock path components. Replica circuits 108 include dummy output buffer 110 , with dummy load capacitance 111 and dummy clock buffer 107 . The dummy components and second delay line 102 constitute a dummy clock path having exactly the same delay time as the internal clock path. Shift register 103 is used for activating a number of delay elements in both delay lines based on a command generated by phase comparator 106 .
Phase comparator 106 compares the dummy clock and the external clock phases which differ by one cycle. This comparison is illustrated in FIGS. 2A, 2 B, 2 C, and 2 D. External dock signal 200 is divided down in divider 105 to produce divided-down external signal 201 . Signal 202 is the signal at the output of dummy delay line 102 . Signal 203 , which is generated inside phase comparator 106 , is a one delay unit delayed output dummy line signal 202 . If both signals 202 and 203 go high before 201 goes low, this means that the output clock is too fast and phase comparator 106 outputs a shift left (SL) command to shift register 103 , as illustrated in FIG. 2 B. Shift register 103 shifts the tap point of delay lines 102 and 101 by one step to the left, increasing the delay. Conversely, if both signals 202 and 203 go high after 201 goes low, this means that the output clock is too slow and phase comparator 106 outputs a shift right (SR) command to shift register 103 , as illustrated in FIG. 2 D. Shift register 103 shifts the tap point of delay lines 102 and 101 by one step to the right, decreasing the delay. If 201 goes low between the time 202 and 203 go high, the internal cycle time is properly adjusted and no shift command is generated, as illustrated in FIG. 2 C. The output of the internal clock path in this case coincides with the rising edge of the external clock and is independent of external factors such as ambient temperature and processing parameters.
A schematic diagram of a conventional Vernier Delay Line (VDL) circuit 300 used for the stages of delay line 101 of FIG. 1 is shown in FIG. 3 . The circuit 300 of FIG. 3 consists of a series of n delay stages, each stage consisting of three NAND gates 305 , 306 and 307 and two inverters 310 , 311 . The unit delay for stage 301 of upper delay line 302 consists of NAND gate 305 and inverter 310 . The upper delay line 302 and tower delay line 303 are connected through NAND switch 306 whose transistor gates become the load for the upper delay line 302 . Shift register 315 provides a signal to open or close NAND switch 306 . The delay of the upper delay line 302 slightly exceeds that of the lower delay line 303 . This delay difference becomes the unit delay time of the VDL circuit 300 .
FIG. 3A illustrates in block diagram form the functioning of the VDL circuit 300 of FIG. 3 . Each unit delay 350 , 351 , 352 , 353 , 354 in upper delay line 302 has a delay time of 1.2 td, and each unit delay 360 , 361 , 362 , 363 , 364 in lower delay line 303 has a delay time of td, where td is the unit delay time of the conventional delay generator. The additional 0.2 td delay of the upper delay line in this example is due to the gate loading from the NAND switches. These unit delays 350 - 354 and 360 - 364 are serially connected through switches 370 , 371 , 372 , 373 , and 374 . If only switch 370 closes, the VDL generates a delay of 5 td from IN node 340 to OUT node 399 . Similarly, if switch 371 closes, the VDL generates a delay time of 5.2 td from IN node 340 to OUT node 399 . Thus, the VDL circuit 300 is capable of generating a delay of every 0.2 td delay time.
Conventional delay lines of DDLLs, however, suffer from numerous drawbacks. One such drawback is that the resolution, i.e., the delay per stage, of the delay line is dependent upon the number of gates for each unit delay of the stage. The larger the number of gates in each unit delay, the larger the unit delay time td. Although the circuit shown in FIG. 3 can generate a delay of every 0.2 td, the resolution is limited by the value of td. The larger the value of td, the lower the resolution possible.
In addition to providing poor resolution, a high value for the unit delay time td can cause problems when the DDLL is placed in a state of minimum delay. A state of minimum delay occurs when the delay between the input and output clock signals is as close to zero as allowed by the parameters of the delay line, i.e., the smallest delay as allowed by the unit delay time td. In this case, if the DDLL attempts to decrease the delay, such decrease would be impossible because the delay line is already at minimum delay. Each unit delay of the delay line shown in FIG. 3 consists of one NAND gate and one inverter. The unit delay time for each unit delay having this construction is approximately 200-300 picoseconds. The minimal delay of the delay line 300 is thus limited to 200-300 picoseconds, without the possibility of decreasing the unit delay time below that time. Thus, the resolution of the delay line, determined by the unit delay time, is limited by the number of gates in each unit delay.
A further drawback of conventional DDLL circuits is the space required to layout the circuitry of the DDLLs. Each stage of the delay line consists of three NAND gates and two inverters for a total of five gates. Each stage could be replicated 50-100 times to target a typical clock input frequency of 100 MHz. This extensive amount of circuitry occupies a significant amount of space within a semiconductor circuit.
Yet another drawback of conventional DDLL circuits is that they are inherently inaccurate due to asymmetries in the delay line design. Each stage of the delay line consists of three NAND gates and two inverters. Unless the pull-up and pull-down times of the transistors forming the inverters and NANDs in each delay element are identical, the output of the delay line will consist of pulses with asymmetrical rising and falling edges as compared to the input signal. This asymmetry leads to differing pulse widths between the input signal and the output signal, as shown in FIG. 5 A. The output signal, therefore, will differ in pulse width from the input signal, which may lead to inaccuracies.
There is a need, therefore, to improve the performance of the delay line in a DDLL circuits by increasing the resolution of the delay line. Additionally, there is a need for improving the configuration of the delay line in DDLL circuits to reduce the amount of space required for the circuitry used to implement the delay line.
SUMMARY OF THE INVENTION
The present invention provides a unique method and apparatus for improving the resolution of a delay line, while also substantially reducing the necessary circuitry and associated space required for layout by reducing the number of gates in each unit delay.
In accordance with the present invention, the gate count for each unit delay is reduced to one gate. Since the number of gates for each unit delay is minimal, the unit delay time is decreased to a minimum, improving the resolution of the delay line.
Furthermore, by reducing the number of gates for each stage of the delay line to a total of three gates (two NAND gates and one inverter), the delay line will occupy approximately 40% less of the area previously occupied by the conventional delay line.
Finally, by reducing the number of gates for each stage of the delay line to a total of three gates, the delay line will result in substantially symmetrical rising and falling edges of the output signal.
These and other advantages and features of the invention will become apparent from the following detailed description of the invention which is provided in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates in block diagram form a known digital delayed lock loop (DDLL) circuit;
FIG. 2A illustrates a timing diagram showing the operation of the DDLL of FIG. 1;
FIG. 2B illustrates a timing diagram showing a faster internal signal than the external signal;
FIG. 2C illustrates a timing diagram showing adjusted internal and external signals;
FIG. 2D illustrates a timing diagram showing a slower internal signal than the external signal;
FIG. 3 illustrates in schematic diagram form a conventional delay line used in a DDLL;
FIG. 3A illustrates in block diagram form the operation of the conventional delay line of FIG. 3;
FIG. 4 illustrates in schematic diagram form a delay line in accordance with the present invention;
FIG. 4A illustrates in block diagram form the operation of the conventional delay line of FIG. 4;
FIG. 5A illustrates a timing chart showing the difference between the pulse width of the input and output signals of the logic delay elements shown in FIG. 3 .
FIG. 5B illustrates a timing chart showing the difference between the pulse width of the input and output signals of the logic circuit delay elements shown FIG. 4;
FIG. 6 is a block diagram showing an implementation of the precharge of the first stage of the delay line of FIG. 4;
FIG. 7 is a block diagram of a printed circuit board (PCB) implementing the DDLL of the present invention; and
FIG. 8 is a block diagram of a computer system implementing the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described as set forth in the preferred embodiments illustrated in FIGS. 4-8. Other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention.
FIG. 4 illustrates in schematic diagram form a delay line circuit 400 in accordance with the present invention. A CLK IN signal is input at node 410 . The delay circuit 400 of FIG. 4 consists of a series of n delay stages, each stage consisting of two NAND gates and one inverter. Each stage is either an odd stage or an even stage, depending upon its position in the line. Thus, the first stage 401 is an even stage, the second stage 411 is an odd stage, a third stage (not shown) would be an even stage, etc. Even stage 401 consists of NAND gates 405 , 406 and inverter 407 . NAND gate 405 acts as a switch connecting together upper delay line 402 and lower delay line 403 . The transistor gates of NAND switch 405 become the load for the upper delay line 402 . Shift register 415 provides a signal to open or close NAND switch 405 . The delay of the lower delay line 403 slightly exceeds that of the upper delay line 402 . This delay difference becomes the unit delay time of the delay line circuit 400 .
By reducing the gate count of the unit delay to one gate, i.e. inverter 407 , the unit delay time td is reduced to approximately 50 picoseconds. By reducing the unit delay time td, the resolution of each stage is increased.
FIG. 4A illustrates in block diagram form the functioning of the circuit 400 of FIG. 4 . Each unit delay 450 , 451 , 452 , 453 , 454 in upper delay line 402 has a delay time of td, and each unit delay 460 , 461 , 462 , 463 , 464 in lower delay line 403 has a delay time of td+Δ, where td is the unit delay time of the delay generator. These unit delays 450 - 454 and 460 - 464 are serially connected through switches 470 , 471 , 472 , 473 , and 474 . If only switch 470 closes, the circuit generates a delay of 5(td+Δ) from IN node 440 to OUT node 499 . Similarly, if switch 471 closes, the circuit generates a delay of td+4(td+Δ) from IN node 440 to OUT node 499 . Since the unit time delay of the circuit 400 is now 50 picoseconds as compared to the prior art of 200-300 picoseconds, the resolution of the delay time is significantly increased.
Another aspect of the structure of delay stage 401 of delay circuit 400 is that because of the relatively low number of gates, it provides substantially symmetrical pulse widths for the input signal and output signal. This is depicted in FIG. 5B, where PW 1 ′ is very close to PW 2 ′. This is a significant advantage over the prior art shown in FIG. 3, where each delay stage consists of five gates. Because the transistors forming the inverters and the NAND gates in each delay element do not have identical rise and decay times, the signal at the output of the prior art delay line circuit 300 has asymmetrical rising and falling edges as compared to the input signal. The output signal will therefore differ in pulse width from the input signal, leading to inaccuracies.
A further aspect of the structure of delay line circuit 400 is the significant reduction in the amount 6 f gates necessary to implement the delay line. Each stage of the delay line circuit 400 consists of a total of three gates, i.e. two NANDs and one inverter. Each stage of the prior art line delay circuit 300 consists of five total gates, i.e. three NANDs and two inverters. The reduction of the total number of gates from five to three by the present invention allows the delay line circuit 400 to occupy approximately 40% less space than the prior art circuit 300 . This results in significant savings when each stage is replicated 50-100 times to target a clock input frequency of 100 MHz.
In order to implement the delay line circuit 400 into a DDLL, it is necessary to precharge the first stage of the delay line by toggling the first stage input at node 420 between a high logic level, i.e. “1”, and a low logic level, i.e. “0”, for every cycle that a new switch is enabled over the previous cycle. When the switch selected is an even switch, node 420 must be precharged to a logic high level, i.e. “1.” When the switch selected is an odd switch, node 240 must be precharged to a logic low level, i.e. “1”.
FIG. 6 illustrates in block diagram form a DDLL circuit 600 which uses the delay line circuit 400 in accordance with the present invention. DDLL circuit 600 consists of delay line circuit 400 , shift register 605 , phase detect 610 , and control circuitry to perform the necessary precharging of the first stage of delay line circuit 400 , which consists of a gate 620 , which can be either an OR gate as shown or an exclusive OR (XOR) gate, and T flip-flop 621 .
The precharging is done in the following manner. The shift left (SL) and shift right (SR) signals sent from the phase detect circuit 610 to shift register 605 are input into the gate 620 . The output of gate 620 is input into T Flip-flop 621 . The output of T Flip-flop 621 is connected to node 420 of delay line circuit 400 . T Flip-flop 621 will maintain its binary state, i.e. either a “0” or a “1” until directed by the input signal from gate 620 to switch states. In order to select a new switch in delay line circuit 400 , phase detect 610 will send a signal to shift register 605 , indicating either a shift left (SL) or shift right (SR) depending upon the shift required to synchronize the clock pulses. The signals on the SL and SR lines are input into the gate 620 . If either of the output lines from the phase detect goes high, indicating a shift is required and a new switch is being chosen, the output of gate 620 will cause the T Flip-flop 621 to change states, i.e. toggle. If no shift is necessary, a new switch need not be selected, and T Flip-flop will not toggle. Thus, the appropriate signal will be applied to the input node 420 of delay line circuit 400 .
FIG. 7 shows printed circuit board (PCB) 700 with multiple ICs 701 , 702 , 704 having differences in the phases of the IC generated internal clocks. DDLL 703 operates to align the phases of the internally generated clock signals of ICs 701 and 702 utilizing a delay line according to the present invention. PCB 700 could be used in a computer system where one of ICs 701 and 702 is a microprocessor and the other is a memory device, a storage device controller, or an input/output device controller.
A typical processor system which includes a DDLL according to the present invention is illustrated generally at 800 in FIG. 8. A computer system is exemplary of a device having digital circuits which require synchronization of the components in the system. Other types of dedicated processing systems, e.g. radio systems, television systems, GPS receiver systems, telephones and telephone systems also contain electronic circuits which can utilize the present invention.
A processor system, such as a computer system, generally comprises a central processing unit (CPU) 844 that communicates to an input/output (I/O) device 842 over a bus 852 . A second I/O device 846 is illustrated, but may not be necessary depending upon the system requirements. The computer system 800 also includes random access memory (RAM) 848 , read only memory (ROM) 850 , and may include peripheral devices such as a floppy disk drive 854 and a compact disk (CD) ROM drive 856 which also communicate with CPU 844 over the bus 852 . A DDLL circuit 860 in accordance with the present invention as described with respect to FIG. 6 is included in the system.
Utilizing the method of the present invention, the phases of the internally generated clock signals of the ICs in each of the devices can be aligned. It must be noted that the exact architecture of the computer system 800 is not important and that any combination of computer compatible devices may be incorporated into the system.
Reference has been made to preferred embodiments in describing the invention. However, additions, deletions, substitutions, or other modifications which would fall within the scope of the invention defined in the claims may be found by those skilled in the art and familiar with the disclosure of the invention. Any modifications coming within the spirit and scope of the following claims are to be considered part of the present invention. | 4y
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This is a Divisional of application Ser. No. 08/234,743 filed Apr. 28, 1994, now U.S. Pat. No. 5,431,235.
BACKGROUND OF THE INVENTION
This invention relates generally to paving breakers, and more particularly to an apparatus on a paving breaker for retaining and stabilizing a moil in the fronthead of a paving breaker.
The traditional handheld paving breaker design consists of a piston transferring energy through an anvil block to a moil. One of the purposes of the anvil block is to keep the moil point on the working surface, as pressurized air enters the breaker. However, a 15 percent loss of power is incurred during the transfer of energy through the anvil block. To maximize power, the anvil block can be eliminated. However, with no anvil block, the problem of stabilizing the moil increases. The moil tends to bounce from the work surface, making operation of the breaker difficult.
The foregoing illustrates limitations known to exist in present paving breakers. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
In one aspect of the present invention, this is accomplished by providing a paving breaker having a housing forming a first bore with a longitudinal axis extending therethrough and a piston in said first bore reciprocal along said longitudinal axis; a moil retaining apparatus comprising: piston bearing means in said first bore extending longitudinally within said housing for slidably supporting an end of said piston, said piston bearing means forming a second bore concentric with said first bore around said axis; a front head extending longitudinally from within said housing, said front head forming a third bore concentric with said first and second bores around said axis; latch means on said front head for releasably holding a moil in said front head; reciprocal chuck means extending longitudinally within said front head for slidably holding a top end of a moil, said chuck means forming a fourth bore concentric with said first, second and third bores around said axis, said chuck means being slidable longitudinally in said front head between a first and second stop position; biasing means in said housing, for biasing said chuck means longitudinally toward said fronthead; retainer means in said fronthead for permitting longitudinal movement of said chuck means, while restraining rotational movement of said chuck means; first mounting means for releasably mounting said piston bearing means in said housing; and second mounting means for releasably mounting said chuck means in said front head.
The foregoing and other aspects will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a schematic elevational view of a front portion of a paving breaker, in cross-section, with parts removed, showing the reciprocal chuck of this invention in a first stop position;
FIG. 2 is a view similar to FIG. 1, showing the reciprocal chuck of this invention in a second stop position;
FIG. 3 is schematic plan view of a front portion of a paving breaker, in cross-section, with parts removed, showing a chuck restrained from rotational movement in a fronthead by two rivets, the fronthead being shown in the housing of the paving breaker; and
FIG. 4 is an isometric schematic view of the reciprocal chuck of this invention.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2, a paving breaker is shown generally as 1, having a housing 3 that forms a first bore 5, with a longitudinal center axis 7 extending therethrough. A piston 9 in first bore 5 is reciprocal along axis 7, as is well known. The back end of the paving breaker 1 is not shown, but includes an back head, with operator control handles thereon, as well as entrance and exhaust ports for transmitting compressed air through the breaker to operate the piston, as is well known.
Piston bearing means 11 in first bore 5 extends longitudinally within housing 3 for slidably supporting an end 13 of piston 9. Piston bearing means 11 forms a second bore 15 concentric with first bore 5, around axis 7. A front head 20 extends longitudinally from within housing 3. Front head 20 forms a third bore 22 concentric with first bore 5 and second bore 15. Front head 20 is held in housing 3 by a nut and bolt fastener 24 compressing housing 3 around fronthead 20, as is well known.
A conventional latch means 26 is mounted on fronthead 20 for releasably holding a moil 28 (shown in phantom) in fronthead 20. Latch means 26 includes a latch handle 30 pivotable about a pivot pin 32 that is mounted on fronthead 20. A spring biased plunger 34 rides on latch head 36 as latch handle is pivoted between an open and closed position. With latch 26 in the open position, plunger 34 rests in depression 38 to provide a detent, or holding action, as is well known. Other types of latch mechanisms will work.
A reciprocal chuck means 40 extends longitudinally outwardly from within front head 20. Chuck means 40 forms a fourth bore 42 concentric with first bore 5, second bore 15 and third bore 22, around axis 7. Chuck means 40 slidably retains a top end 46 of moil 28. Chuck means 40 is slidable longitudinally in fronthead 20 between a first and second stop position, as described hereinafter.
Biasing means 50 in housing 3 biases chuck means 40 toward fronthead 20, so as to force moil 28 into contact with the work surface, not shown, as a way of controlling moil 28 during start-up of the breaker. Biasing means 50 is preferably an elastic spring 52 compressible between a bottom end 54 of piston bearing means 11 and a top end 56 of chuck means 40. Other types of elastic biasing will work, such as pneumatic, or hydraulic means.
Retainer means 60 in fronthead 20 permits longitudinal movement of chuck means 40, while simultaneously restraining chuck means 40 from rotational movement, as described hereinafter.
First mounting means 62 releasably mounts piston bearing means 40 in housing 3. First mounting means 62 is preferred to be an elastic split ring 64, as is well known. Second mounting means 66 releasably mounts chuck means 40 in front head 20. Second mounting means 66 is preferred to be an elastic split ring 68, as is well known. First split ring 64 is positioned in a circumferential groove 70 in an inner surface of housing 3. Split ring 64 extends into first bore 5 (FIGS. 1 and 2), to contact bottom end 54 of piston bearing means 11 and top end 72 of fronthead 20. Second split ring 68 is positioned in a circumferential groove 74 in an inner surface of fronthead 20. Split ring 68 extends into fourth bore 42 (FIGS. 1 and 2), to contact, as a stop, bottom end 76 of chuck means 40.
Now referring to FIG. 4, the chuck 80 of the invention is shown. Chuck 80 comprises an elongated tubular body 82 terminating at top end 84 and bottom end 86. Top end 84 forms a top shoulder portion 88 for seating spring 52. Body 82 has an inner surface 90 forming fourth bore 42. As viewed in a horizontal cross-section (FIG. 3), inner surface 90 is polygonal in shape, similar to top portion 46 of moil 28, so that moil 28 can reciprocate in chuck 80, but it cannot rotate therein. Body 82 has an external surface 92 extending between top end 84 and bottom end 86. External surface 92, adjacent bottom end 86, forms a radially extending collar 94, with a sloped contact shoulder 96 thereon, for stopping chuck 80 at a first stop position, as described hereinafter. Body 82, at bottom end 86, forms a bottom shoulder 100 (FIGS. 1 and 2) comprising, at a first portion 102, a surface for contacting, as a stop, a protruding moil collar 104, shown in phantom in (FIGS. 1 and 2).
At a second portion of bottom end 86 is provided a grooved surface 106 for contacting split ring 68 to provide a second stop position for chuck 80, as described hereinafter. Body 82 also includes at least one longitudinally extending keyway 108 between top end 84 and bottom end 86. Keyway 108 receives retainer means 60 therein. We prefer two keyways, diametrically oppositely spaced around a perimeter formed by external surface 92, with each keyway 108 receiving a retainer means 60. Retainer means 60 permits longitudinal movement of chuck 80, but simultaneously restrains rotational movement thereof.
Now referring to FIGS. 1,2 and 3, the retaining means 60 will be further described. At least one radially extending bore 110 is positioned in a sidewall 112 of fronthead 20. Bore 110 ends at a bottom surface 114 within sidewall 112. Extending the rest of the way through sidewall 112 is an aperture 116 between bottom surface 114 and third bore 22. A removable rivet 120 is positioned in bore 110. Rivet 120 has a head 122 bottomed against bottom surface 114, and a shank 124 radially extending into third bore 22 via aperture 116. Shank 124 is slidably positioned in keyway 108 on chuck 80. We prefer two such retainer means.
Now referring to FIGS. 1 and 2. In order to maximize spring life, a first annular wear pad 130 is positioned between a top end 132 of spring 52 and bottom end 54 of piston bearing means 11. Spring 52 and pad 130 contact a shoulder 134 in second bore 15, formed at the location of change of diameter of second bore 15. A second annular wear pad 136 is positioned between a bottom end 138 of spring 52 and top end 84 of chuck 11. Spring 52 and pad 136 contact a shoulder 88 on top end 84 of chuck 80, formed at a location of change of diameter of body 82. We prefer the wear pads 130 and 136 to be provided from a nonmetallic material such as an acetal resin supplied by The DuPont Corporation under the registered trademark DELRIN II.
In assembling the breaker, piston bearing means 11 is telescoped into housing 3, and split ring 64 is snapped into place. Rivets 120 are placed into bores 110 and fronthead 20 is placed in housing 3. Chuck 80 is telescoped into housing 3, aligning keyways 108 with shanks 124. Bolt and nut 24 are tightened to lock the assembly in place. Split ring 68 is snapped into groove 74. Finally, moil 28 is inserted into chuck 80 and latch means 26 is closed.
FIG. 1 shows the arrangement of the assembly when the moil 28 is just barely in contact with the work surface, with only the weight of the housing 3 acting on the spring 52. Chuck 80 is in the first stop position wherein collar 94 and groove portion 106 are forced against split ring 68 by spring 52.
FIG. 2 shows the arrangement of the assembly when the breaker is being operated, with an operator pressing on the breaker. Spring 52 is compressed, and chuck 80 is in the second stop position, wherein sloped surface 94 contacts and stops against a shoulder 140 formed on the internal surface of front head 20, shoulder 140 extending radially into third bore 22.
It should be understood that the terms "top" or "bottom" as used herein refer to the orientation of elements of the breaker, with the work surface horizontal and the breaker held in the normal vertical working position. A rotation of the breaker out of vertical would rotate the "top" and "bottom" orientation along therewith. | 4y
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ORIGIN OF THE INVENTION
The invention described herein was made in the performance of work under a NASA contract and is subject to the provisions of Section 305 of the National Aeronautics and Space Act of 1958, Public Law 83-568 (72 Stat. 435; 42 USC 2457).
This is a division of application Ser. No. 718,104, filed Aug. 27, 1976 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to uniformly-sized, small microspheres, to methods of making the microspheres and to their use in labeling biological cell surfaces.
2. Description of the Prior Art
The isolation and characterization of cell membranes and their components is essential for an understanding of the role in which surface membranes play in regulating a wide variety of biological and immunological activities. The present techniques used for this purpose are not quite satisfactory.
Knowledge of the nature, number and distribution of specific receptors on cell surfaces is of central importance for an understanding of the molecular basis underlying such biological phenomena as cell-cell recognition in development, cell communication and regulation by hormones and chemical transmitters, and differences in normal and tumor cell surfaces. In previous studies, the localization of antigens and carbohydrate residues on the surface of cells, notably red blood cells and lymphocytes, has been determined by bonding antibodies or lectins to such macromolecules as ferritin, hemocyanin or peroxidase which have served as markers for transmission electron microscopy. With advances in high resolution scanning electron microscopy (SEM), however, the topographical distribution of molecular receptors on the surfaces of cell and tissue specimens can be readily determined by similar histochemical techniques using newly developed markers resolvable by SEM.
Recently commercially available polystyrene latex particles have been utilized as immunologic markers for use in the SEM technique. The surface of such polystyrene particles is hydrophobic and hence certain types of macromolecules such as antibodies are absorbed on the surface under carefully controlled conditions. However, such particles stick non-specifically to many surfaces and molecules and this seriously limits their broad application.
The preparation of small, stable spherical particles which are bio-compatible, i.e., do not interact non-specifically with cells or other biological components and which contain functional groups to which specific proteins and other bio-chemical molecules can be covalently bonded is disclosed in copending application Ser. No. 434,124, filed Jan. 17, 1974, now issued on May 18, 1976, as U.S. Pat. No. 3,957,741.
Smaller, more evenly shaped microspheres are disclosed in Ser. No. 634,935, filed Nov. 24, 1975, now issued on Feb. 6, 1979, as U.S. Pat. No. 4,138,383 and microspheres having a density differing from that of cell membranes are disclosed in Ser. No. 634,929, filed Nov. 24, 1975, now issued on July 12, 1977, as U.S. Pat. No. 4,035,316.
The hydroxyl groups can be activated by cyanogen bromide for covalent bonding of proteins and other chemicals containing amino groups to the polymericlatex. Methacrylic acid residues which impart a negative charge onto the particles are likely to prevent non-specific binding to cell surfaces and to provide carboxyl groups to which a variety of bio-chemical molecules can be covalently bonded using the carbodiimide method. Cross-linking of the polymeric matrix is preferable in order to maintain the stability and size of the particles in both aqueous solution and in organic solvents commonly used in the fixation and dehydration of biological specimens for electron or light microscopy.
Microspheres, 150-350 A in diameter serve as markers for transmission electron microscopy as well as in high resolution scanning electron microscopy. Microspheres larger than 0.2 micron in diameter can be utilized with ordinary visual microscopy. However, the attachment of fluorescent tags to the surface required a covalent bonding reaction and the distribution of tags was not totally uniform and the attachment resulted in a consumption of covalent bonding sites which would otherwise be available for marking with antigen, lectin or antibody.
SUMMARY OF THE INVENTION
Highly fluorescent, stable, biocompatible microspheres are produced in accordance with this invention by addition polymerization of an aqueous dispersion monomer mixture containing an acrylic monomer substituted with a covalent bonding group and an addition polymerizable fluorescent comonomer. Free radicals may be generated by free radical catalysts or by high energy radiation. More uniformly sized and shaped beads are formed from very dilute aqueous monomer systems. Surfactants may be present which aid in steric stabilization and permit the use of relatively high concentration of monomers (up to about 20%).
The microsphere can be utilized to yield a biochemical mapping of the membrane with respect to assessment of surface receptors which can redistribute in the plane of the membrane in response to a matrix containing rigidly displayed ligands. This will be useful in determining the contributing roles of the restriction of movement of certain surface receptors to oncogenic transformation of cells. Other applications include the isolation of differentiated regions of cell surface membranes, and studies of this nature would be of great utility in areas such as development biology.
The microspherical beads containing hydroxyl or amine groups covalently bond to antibodies and other biological materials and are useful as specific cell surface markers for scanning electron microscopy. The particles are found to bind to hormones, toxins, lectins, antibodies, sugars and other molecules and have application in the detection and localization of a variety of cell surface receptors. Particles tagged with fluorescent dye or radioactive molecules serve as sensitive markers for fluorescent microscopy and as reagents for quantitative study of cell surface components. By covalently bonding lectins, antigens, hormones and other molecules to these spheres, detection and localization of specific carbohydrate residues, antibodies, hormone receptors and other specific cell surface components or fragments can also be isolated and determined. These reagents also have application in highly sensitive radioimmune assays, as visual markers for fluorescent and transmission electron microscopy, for radioactive quantitation of specific cell surface receptors and as potential thereapeutic reagents.
The microspheres are hydrophilic, hydrolytically stable, biocompatible and have good mechanical strength. The microspheres are of well characterized structure, of outstanding purity and the hydrophilic properties, size, and mechanical properties can be systematically varied by selection of monomers and polymerization conditions.
These and many other features attendant advantages of the invention will become apparent as the invention becomes better understood by reference to the following detailed description.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The microspheres are preferably produced by aqueous suspension addition polymerization of a monomer mixture including at least 10%, by weight, of an olefinically unsaturated monomer containing a covalent bonding group such as hydroxyl, carboxyl or amino. Polymerization may be initiated by means of a free radical catalyst such as 0.003 to 0.1 percent by weight of a persulfate such as ammonium persulfate or a peroxide, hydroperoxide or percarbonate.
It is preferred that the aqueous suspension polymerization be conducted in absence of free radical catalyst. Polymerization can proceed by heat alone at temperatures above 50° C. However, it is preferred to conduct the addition polymerization at lower temperature by means of high energy radiation.
The polymerization proceeds with or without stirring with application of high energy radiation capable of generating free radicals in the aqueous system. The radiation source is suitably a cobalt 60 gamma source or cesium source and doses of 0.5 to 1.0 megarads are sufficient for polymerization. The reaction is preferably conducted under oxygen excluding condition, generally by applying vacuum to the reaction vessel or by displacing oxygen gas from the system with an inert gas such as nitrogen. After polymerization has proceeded to completion, the reaction mixture is made neutral by adding acid or base, passed through mixed ion exchange resins to remove emulsifiers. Further purification is achieved by centrifugation on a sucrose gradient.
The addition of 0.05 to 5%, by weight, of a stabilizing agent to the aqueous polymerization system before polymerization is found to further reduce agglomeration. The stabilizing agent is suitably an aqueous soluble polymer such as a polyalkylene oxide polyether or nonionic surfactants such as Tween which are polyoxyethylene derivatives of fatty acid partial esters of sorbitol, Triton X, or dextrans. The polyethers generally have a molecular weight from 10,000 to 10,000,000, preferably 400,000 to 6,000,000 and are polymers of ethylene oxide, propylene oxide or their mixtures. Polyethylene oxides (PEO) and Triton X are preferred.
Mono-unsaturated covalent bonding monomers are freely water soluble and should comprise from 25-50% of the monomer mixture. These monomers are suitable selected from amino, carboxyl or hydroxyl substituted acrylic monomers. Exemplary monomers are acrylamide (AM), methacrylamide (MAM), acrylic acid, methacrylic acid (MA), dimethylaminomethacrylate or hydroxyl-lower alkyl- or amino-lower-alkyl-acrylates such as those of the formula: ##STR1## where R 1 is hydrogen or lower alkyl of 1-8 carbon atoms, R 2 is alkylene of 1-12 carbon atoms, and Z is --OH or R 3 --N--R 4 where R 3 or R 4 are individually selected from H, lower alkyl, or lower alkoxy of 1-8 carbon atoms. 2-hydroxyethyl methacrylate (HEMA), 3-hydroxypropyl methacrylate and 2-aminoethyl methacrylate are readily available commercially. Porosity and hydrophilicity increase with increasing concentration of monomer.
Inclusion of polyunsaturated compounds also provides cross-linked beads which are less likely to agglomerate. The polyunsaturated compounds are generally present in the monomer mixture in an amount from 0.1-20% by weight, generally 6-12% by weight and are suitably a compatible liquid diene or triene polyvinyl compound capable of addition polymerization with the covalent bonding monomer such as ethylene glycol dimethacrylate, trimethylol propane trimethacrylate, N,N-methylene-bis-acrylamide (BAM), piperazine ethyl methacrylate or divinyl benzene.
For small particle size the monomer mixture preferably contains a large percentage, suitable from 40-70% of sparingly water soluble monomers having hydrophobic characteristics since this is found to result in freely suspended individual small beads. In the absence of such monomers, the particles are of relatively large diameter. The cross-linking agent is sometimes sparingly water soluble. Hydrophobic characteristics can also be provided with monomers such as lower alkyl acrylates suitably methyl methacrylate or ethyl methacrylate or a vinyl pyridine.
Vinyl pyridines suitable for use in the invention are 2-vinyl pyridine, 4-vinyl pyridine and 2-methyl-5-vinyl pyridine. 2-vinyl pyridine has, in general, been found to produce smaller beads, more resistant to agglomeration even in the absence of cross-linking agents and suspending agents.
The fluorescent monomer is present in the monomer mixture in an amount sufficient to provide adequate fluorescence to the microspheres, suitably at least 0.1% to 15% by weight, generally from 1 to 10% by weight thereof. The fluorescent monomer contains a fluorochrome portion to which is attached at least one addition polymerizable group such as an ethylenically unsaturated vinyl or allyl group. Fluorochromes absorb incident radiation, attain an excited state and emit visible light when stimulated by shorter wavelength light. Fluorescence efficiency, the ratio of quanta emitted to quanta absorbed is generally from 0.1 to 0.8 and should not be effected by modification of the fluorochrome molecule necessary to add the olefinic group.
Fluorochromes suitable for conjugation of proteins can readily be converted to addition polymerizable monomers suitable for use in this invention by reaction with an unsaturated compound containing a functional group condensible with the protein conjugation group. For example, fluorochromes containing sulfonic acid or sulfonyl chloride groups can be reacted with amine substituted olefins to form a sulfonamide linkage. The reaction can be generalized as follows:
Fluorochrome-A+B-Olefin→Fluorochrome-AB-Olefin
where A is the fluorochrome functional group, B is a cocondensible group and AB is the condensation residue. Suitable A, B, AB pairs follow:
______________________________________A B AB______________________________________OH NCO urethaneNH.sub.2 NCO ureaCOOH OH esterCOCl OH esterCOOH NH.sub.2 amideCOCl NH.sub.2 amideSCN NH.sub.2 thioureaNH.sub.2 COOH amideOH COOH esterSO.sub.3 H NH.sub.2 sulfonamideSO.sub.2 Cl NH.sub.2 sulfonamide______________________________________
Representative B-Olefin materials are allyl amine, hydroxy or amino alkyl acrylates as previously described, methacrylic anhydride or methacryloyl chloride.
It is also possible to form an adduct of the dye and a difunctional BB compound before reaction with B'-Olefin. For example:
Fluorochrome-A+B-B→Fluorochrome-AB-B ##STR2##
A sulfonyl chloride dye could be reacted with a diamine and then with an unsaturated acyl chloride.
Representative functionally substituted fluorochrome dyes are dansyl chloride (sulfonyl chloride of 1-dimethylaminonaphthalene-5-sulfonic acid), tetramethylrhodamine isothiocyanate (TDIC), fluorescein isothiocyanate (FITC), fluorescamine, RB 200 sulfonyl chloride, fluorescein carbonyl chloride, aminofluorescein, ethidium bromide and the like.
The allyl monomers are difficult to copolymerize by free radical catalysis and the reaction with the functional acrylic monomers may be a grafting addition reaction. Examples of practice follow.
EXAMPLE 1
Dansyl allyl amine, a fluorescent monomer, was synthesized by reacting allyl amine (5 mmol) with dansyl chloride (5 mmol) in acetone (50 cc) in the presence of triethylamine (5 mmol) for 6 hours at 0° C., evaporating to dryness and dissolving the residue in dichloromethane. The solution was washed with sodium bicarbonate solution (3%) and a dilute solution of acetic acid (3%). After drying, it was recrystalized from petroleum ether (mp 81° C.). Its ir spectrum shows a NH stretch at 3280 cm -1 ; olefinic CH at 3000 cm -1 and C═C at 1650 cm -1 .
EXAMPLE 2
Dansylallylamine (DAA) was copolymerized with covalent bonding monomers as follows:
______________________________________Material Weight, g______________________________________HEMA 9.0BAM 1.0DAA 0.1PEO (M.W. 600,000) 0.8______________________________________
The monomer system diluted to 200 cc with water was irradiated in a Co-gamma source at room temperature in the absence of air for one hour (0.8 mr) yielded fluorescent particles, the diameter of which was 1.7 microns. The diameter was determined in the presence of water by means of a hemacytometer and photography enlargements of microscope pictures. Impurities and PEO were removed by centrifugation several times in distilled water.
EXAMPLE 3
Fluorescein-allyl amine was formed in situ by addition of the two reactants to the monomer mixture before irradiation.
______________________________________Material Weight, g______________________________________HEMA 7.0MA 2.0BAM 1.0Allylamine 0.5FITC 0.05PEO (600,000) 0.8______________________________________
The monomer system was polymerized into fluorescent microspheres having a diameter of 0.7 microns by the procedure described in Example 2.
Potentiometric titrations indicate that the number of carboxyl groups varies from 1.4 to 2.5 per A square. Since one carboxyl group would require an area larger than 1 A square, it is concluded that carboxyl groups are also located inside the microspheres and are accessible to aqueous reagents.
EXAMPLE 4
50 mg of fluorescamine (4-phenylspiro-[furan-2/3H), 1'-phthalan]-3,3' dione) was dissolved in 0.5 g of allylamine, allowed to react over night and evaporated to dryness. The residue was added to 100 c of distilled water containing: 0.4 g of PEO, 1.2 g of HEMA, 0.4 g of methacrylic acid (MA), 1.2 g of acrylamide and 1.2 g of BAM. Nitrogen was passed through the mixture (5 min) which was then irradiated with ionizing radiation from a cobalt-60 source for 3 hours (Total dose: 0.8 megarad). After centrifuging the aqueous suspension and resuspending in water, fluorescent particles were obtained, the average diameter of which was 0.8 microns. The fluorescence intensity was maximum at pH 9 to 10.
EXAMPLE 5
Fluorescent microspheres derivatized with diaminoheptane were coupled to goat antimouse immunoglobulin antibody molecules by a two-step glutaraldehyde reaction, J. Cell Biol. 64, 75 (1975). Murine lymphocytes isolated from a suspension of spleen cells were labeled with the antibody-microsphere conjugates and labeled cells were separated from unlabeled cells by centrifugation. The labeled cells showed strong fluorescence in an ordinary light microscope when illuminated with ultraviolet light.
It is to be realized that only preferred embodiments of the invention have been described and that numerous modifications, substitutions and alterations are all permissable without departing from the spirit or scope of the invention as defined in the following claims. | 4y
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This is a continuation of application Ser. No. 07/895,567, filed on Jun. 5, 1992, now abandoned, which is a continuation of Ser. No. 07/503,814, filed Apr. 3, 1990, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to breath analysis devices, and in particular, to a breath analysis device which is capable of passive or direct sampling of an exhaled breath sample.
Police Departments conducting roadside screening of motorists in relation to breath analysis, are currently required by law to require mouthpiece sampling of the breath when requested by the police officers at a random breath testing station. This process involves the officer requesting that a sample of breath be given through a mouthpiece to an instrument, to which the police officer will take appropriate action according to the result. Currently all breath testing is conducted in this way and the Police Departments have a mammoth task in purchasing and distributing many thousands of mouthpieces each year.
One disadvantage with this is that a mouthpiece is used for each random breath test, and the cost of using such mouthpieces is unnecessary if the motorist has not been drinking or consumed any alcohol in the last few hours.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a breath analysis device which obviates the need to use a mouthpiece on all random breath testing occasions.
According to one aspect of the present invention there is disclosed a dual breath analysis device having a passive first mode of testing and analysing an exhaled breath sample without use of a mouthpiece, and a direct second mode of testing and analysing a second breath sample through a mouthpiece apparatus.
The use of the dual breath analysis device of the present invention is to eliminate the need to use a mouthpiece for those motorists who have not taken a drink in recent hours whereas the remaining small percentage of motorists showing a positive alcohol presence during the passive testing mode will then go through a standard deliverance of a breath sample using a mouthpiece in the direct second mode.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the present invention will now be described with reference to the drawings in which:
FIG. 1 is a perspective view of a hand held device of the preferred embodiment;
FIG. 2 is a flow diagram of the operation of the device of the preferred embodiment; and
FIG. 3 is a display table illustrating the different displays of the device of the preferred embodiment; and
FIG. 4 illustrates the operating components of the system.
DETAILED DESCRIPTION OF THE INVENTION
The device 1 illustrated in FIG. 1 comprises a hand held housing 2 having a display 3, a push button 4, a sensor (not shown), a sample port (not shown) and a fuel cell (not illustrated) for testing alcohol content of the sampled breath.
The device 1 uses four AA cells and has automatic power shut-off after five minutes of inactivity. The device is capable of conducting at least 800 passive and direct breath tests on one set of batteries. The display 3 which is an alpha-numeric LCD read out has backlighting for night time use. A microprocessor (not illustrated) automatically eliminates the read out at pre-programmed time.
The single push-button 4 is provided to select a number of operational modes through multiple actuation. The number of operational modes includes:
A. Passive Testing
B. Direct Testing with Low Volume Override
C. Battery/Testing Life
D. Diagnostic Check
E. Print Data
F. Auto Calibration
Mode D, E, and F are supervisory only and provide for mode alterations using an external module.
The microprocessor also records both modes of breath testing. The passive test is recorded as either a pass or fail and if a direct test was conducted after a fail was recorded, the direct test records specific details of date, time, breath alcohol content, and pass or fail.
The print data mode is used to download a stored information onto a printer via a RS232 port. Sufficient capacity is available for the results of two weeks of daily roadside testing.
The device is provided with a diagnostic check which provides for ease of servicing and setting up procedures for real time clock and checks of instruments operating parameters, exclusively only through the supervisory mode.
Another mode which requests a supervisory pass word in order to enter the mode of operation which concerns fine tuning of the instrument calibration is the automatic calibration mode. A known simulator solution is used and the instrument is calibrated by pressing the button to correct the span shown on the LCD. This mode provides a calibrator range of ±30% and shows a "Out of Service" command if a service is required.
Fuel Cell Response Analysis
The output voltage of a fuel cell of this type as a result of receiving a sample of oxidizable gas has been examined (Huck, 1969).
Examples of the response of a typical cell to individual samples of ethyl and methyl alcohols are well documented. The equation that has been proposed is: ##STR1## where k1=reation rate at the electrode (sec-1)
k2=discharge rate of the cell (sec-1)
Vo=maximum voltage achieved on open circuit
The determination of k1 and k2 by numerical analysis routines can be difficult and iterative procedures can prove to be unstable in functions of this form. However, we are not primarily interested in the amplitude and so if we apply the transformation ##EQU1## we obtain
Z(t)=exp (-k1t)+exp(-k2)
This function poses a relatively simple task for analysis. Examining the function at three time values, t, 2t, 4t, yields z(t), z(2t) and hence ##EQU2##
The response of several fuel cells to samples of ethyl alcohol and for other alcohols including methyl, butan-l-ol, propan-l-ol was examined. The error in the value of k1 obtained for these alcohols showed a trend suggesting a deviation from equation (4) to include higher orders of k1. This investigation will continue. However, values of z(t) with the range of alcohols studies showed excellent descrimination for values of t in a particular time range. This was the basis of a technique to show the presence of trace contaminants in a sample of ethyl alcohol.
The device also ensures a delivery of a prescribed amount of deep alveolar air using a pressure transducer volumetric measurement system which ensures that a person delivers a minimum of 1.3 liters of breath when the instrument is in the direct sampling mode, thus enhancing the overall accuracy of the instrument.
The microprocessor is incorporated to provide multiple functions which include:
a) Control of all modes
b) Actuate the dual pumping systems
c) Indicate the conditions of operation
d) Record data logging of daily testing
e) Provide user information and assistance
FIG. 4 illustrates the operating components of the system. The microprocessor 52 is coupled to the fuel cell 48, the dual pumping system 46, and the pressure transducer volumetric measurement system 50. The mouthpiece 42 can be utilized with the inlet port 44 for obtaining the sample.
The foregoing describes only one embodiment of the present invention, and modifications obvious to those skilled in the art can be made thereto without departing from the scope of the present invention. | 4y
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RELATED APPLICATION(S)
This application is a Divisional of U.S. application Ser. No. 10/262,599 filed Oct. 1, 2002 now U.S. Pat. No. 5,947,283 which is incorporated herein by reference
Electronic devices, such as integrated circuit (IC) chip packages, are well known and commonly used to perform a variety of electronic functions. In use, it has been found that some electronic devices often produce significant levels of heat. As a consequence, various methods have been employed to assist in cooling electronic devices.
One well-known method for cooling IC chip packages, for example, involves mounting a device known as a heat sink to a surface of the IC chip package. The heat sink commonly has a flat surface which contacts a surface of the IC chip package. Commonly, a plurality of fins or pins extend substantially perpendicularly from a surface of the heat sink. The protruding pins assist in transporting thermal energy away from the IC chip package by providing a relatively large surface area for convective heat transfer as compared with the surface are of the IC chip package. The heat sink is fabricated from a material having a high thermal conductivity for efficient thermal transfer between the IC chip package and the surrounding environment.
Various methods have been used to mount heat sinks to the surface of IC chip packages. The art has recognized certain advantages of avoiding the use of adhesives, screws, bolts and the like, and has often relied on the use of retaining clips.
FIG. 1 is a perspective view of a prior art assembly of a heat sink 10 which includes a heat sink plate 11 , an electronic device 20 , a mounting frame or base 30 and a retaining clip 40 . It shows the prior art heat sink 10 in an assembled configuration with electronic device 20 coupled to mounting frame 30 and heat sink 10 placed upon and in contact with electronic device 20 . Heat sink 10 is thermally coupled to the top surface of the electronic device 20 by clip 40 , the distal ends or legs 42 of which are engaged with tabs 12 that project from opposite sides of mounting frame 30 .
Once legs 42 of clip 40 are secured under tabs 12 , clip 40 provides a spring bias force to the heat sink 10 relative to base 30 , thereby forcing a surface of heat sink 10 into contact with the surface of the electronic device 20 . In this embodiment of a prior art clip 40 , the clip comprises a bent wire having two distal legs 42 extending from an elongated clip central portion 44 which extends therebetween. As shown in FIG. 2 , legs 42 are substantially perpendicular to central portion 44 , and extend, in the embodiment shown, from central portion 44 in opposing directions forming clip 40 into what may be described as a generally Z-shaped configuration. Further, mounting frame 30 as shown in FIG. 2 is coupled to a substrate 50 , such as a printed circuit board.
In the prior art arrangement of FIG. 1 , the clip central portion 44 is received within a longitudinal groove 52 that is defined between adjacent rows of heat sink pins 54 . The clip central portion 44 is oriented substantially parallel to and rests upon heat sink surface 56 of plate 11 from which pins 54 project.
In the arrangement shown in FIG. 1 , heat sink 10 is secured to the electronic device 20 by tucking an leg or attachment portion 42 of clip 40 under the projecting tabs 12 of the base 30 upon which the electronic device 20 is mounted. Tucking the legs 42 under the tabs 12 provides a torsional spring-bias force to clip 40 that forces clip central portion 44 firmly against heat sink top surface 56 in longitudinal groove 52 . This spring-bias secures heat sink 10 against electronic device 20 to enable good thermal contact between the heat sink 10 and the electronic device 20 . It does not, however, restrain the heat sink 10 from longitudinal sliding movement relative clip 40 along groove 52 . Such relative motion between the clip 40 and heat sink 10 along the axis of clip central portion 44 is also referred to herein as lateral movement of the heat sink. This lateral movement is distinguished from vertical movement of the heat sink 10 away from the surface of electronic device 20 .
Further, in the prior art embodiment shown, heat sink 10 and clip 40 comprise two separate parts, which are not secured to each other before assembly with the electronic device 20 . Clip 40 is not secured to the heat sink 10 , but only engages the heat sink 10 when it is mounted with an electronic device 20 . Accordingly, when the heat sink 10 is not attached to electronic device by clip 40 , clip 40 is a loose part. As such, clip 40 may damage other components if it is dropped during assembly. In addition, the clip 40 , being a loose part, precludes preassembly of clip 20 to the heat sink 10 prior to assembly of the heat sink assembly with the electronic device. Attachment of clip 40 to the heat sink 10 prior to assembly provides numerous advantages, such as, but not limited to, ease of assembly during the attachment of the heat sink 10 to the electronic device, reduction of the risks posed by a loose clip 40 including possible damage to other components.
It is well recognized that accurately positioning heat sink 10 relative to electronic device 20 is crucial for proper thermal management. For optimal thermal efficiency, the electronic device 20 should be centered and its contact surface should be aligned under, and in full contact with heat sink 10 such as shown in the sectional elevation view of FIG. 2 . After a surface of heat sink 10 is forced into contact with a surface of the electronic device 20 by the clip 40 , there remains a potential for the heat sink 10 to shift or move laterally along clip central portion 44 relative to the electronic device 20 . Mechanical shock or vibration during transportation and handling, for example, among other possible disturbances, can cause such undesired lateral shifting of the heat sink 10 .
FIG. 3 is a cross-sectional view of an embodiment of a prior art device which illustrates a problem caused by lateral shifting of the heat sink 10 along the central portion 44 of clip 40 from the centered position illustrated in FIG. 2 to a laterally displaced position. Once it is so shifted, heat sink 10 has lost contact with a portion of the top surface of the electronic device 20 . Such lateral heat sink movement is undesirable since it fails to maintain efficient thermal contact between the electronic device 20 and the heat sink 10 .
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, view of a prior art heat sink, electronic device and clip assembly;
FIGS. 2 and 3 are cross-sectional views of a prior art heat sink assembly;
FIG. 4 is a detail of a top view of an embodiment of clip retention apparatus in accordance with the present invention;
FIG. 5 is detail of a top view of another embodiment of a heat sink clip retention apparatus in accordance with the present invention;
FIG. 6 is a cross sectional detail elevation view taken along section line 6 – 6 ′ respectively of FIG. 5 ;
FIGS. 7–12 are cross sectional detail elevation views showing further embodiments of a clip and heat sink assembly with the views taken similarly to the view of FIG. 6 ;
FIGS. 13–16 are top views of further embodiments of heat sink clip retention apparatus in accordance with the present invention; and
FIGS. 17–20 are cross sectional detail elevation views of further embodiments of heat sink clip retention apparatus.
DETAILED DESCRIPTION
In the following detailed description, reference is made to the accompanying drawings, which are not necessarily to scale, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the apparatus and methods can be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice them, and it is to be understood that the embodiments can be combined, or that other embodiments can be utilized and that procedural changes can be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope is defined by the appended claims and their equivalents. In the drawings, like numerals describe substantially similar components throughout the several views.
The following figures refer to an electronic device, for example an integrated circuit (IC) chip package, to which a heat sink is attached with a retaining clip to form a heat sink assembly. The invention is not limited to heat sinks used with electronic circuits in computer assemblies. It works with any apparatus having a heat emitting device and a heat sink.
Heat sink 10 is manufactured from a material having good thermal conductivity, such as, but not limited to, aluminum and copper. This allows for the efficient conduction of heat from the electronic device 20 to the heat sink 10 . Heat is subsequently conducted through the heat sink plate to the pins 54 and transferred to the surrounding environment by convection and radiation.
In one embodiment of the invention, mounting frame 30 incorporates a clip attachment structure, such as the tab 12 shown in FIG. 1 , to cooperate with the leg portions 42 extending from the ends of clip 40 . The clip attachment tab structure tab 12 projects from opposite sides of mounting frame 30 . In other embodiments, clip attachment structure 12 may be a pocket, protrusion, ledge, or an aperture. The choice of the particular configuration for an attachment structure 12 may depend the specific geometry of the chip mounting arrangement used.
In many of the embodiments of the present invention which are illustrated, clip 40 is a formed cylindrical metal wire. In other embodiments the clip 40 may take the form of, for example, but not limited to, a strap, a band, or a flat wire. The clip 40 can be formed from any material suitable for the intended use, such as, but not limited to, metal and plastic.
In one embodiment, clip 40 is comprised of a resilient material, such that when it is twisted it produces a torsional spring-bias force tending to return to an original shape. In one embodiment, the clip 40 comprises a spring metal.
A thermal conduction aid 26 is commonly applied to the top surface of the electronic device 20 . Thermal conduction aid 26 makes a thermally efficient contact between the mating surface 24 of electronic device 20 and heat sink plate 11 . Examples of suitable thermal conduction aids 26 include, but are not limited to, thermal conductive grease, soft metallic foil, and metal-impregnated paste.
FIG. 4 is a top plan view of an embodiment of the invention. In the embodiment shown, heat sink 10 has a plurality of pins 54 extending upwardly from a surface 56 of heat sink plate 11 . The pins 54 are arranged in longitudinally and transversely oriented rows defining lateral longitudinal grooves 52 aligned with central portion 44 of clip 40 and lateral transverse grooves 53 which are substantially perpendicular to grooves 52 . Longitudinal grooves 52 and, in some cases transverse grooves 53 , are adapted for receiving clip central portion 44 .
One or more of pins 54 has a retaining member 62 projecting from the surface thereof into groove 52 for retaining the clip central portion 44 in groove 52 . Various embodiments characterized by different configurations of retaining member 62 are also illustrated in FIGS. 5 through 12 below.
In some embodiments retaining member 62 is adapted to allow the insertion of clip central portion 44 into groove 52 to retain clip 40 within groove 52 . One skilled in the art can appreciate that the retaining member 62 projecting from pin 54 can, in further embodiments, take other suitable forms and still function to readily allow the attachment of the clip 40 to the heat sink 10 while resisting unintended separation from it. Retaining members 62 can be provided on just a single pin 54 or can be provided on multiple pins 54 along one or both sides of the groove 52 , as will be discussed in connection with the embodiments of the following examples.
FIG. 5 is a top plan view of an embodiment of the assembly where pins 54 are longitudinally extended as fins 55 that extend substantially along the entire length of groove 52 cross the entire width of surface 56 of heat sink plate 11 . Retaining member 62 is provided on a fin 55 which defines one wall of a longitudinal groove 52 . Retaining member 62 keeps central clip portion 44 vertically restrained in groove 52 .
Retaining member 62 is shown in various embodiments in FIGS. 5–9 . In one embodiment, the retaining member 62 may extend for only a portion of the length of the fin 55 . In the embodiment shown in FIG. 5 , the retaining member 62 extends substantially the entire length of the fin 55 . In yet another embodiment, not shown, a plurality of retaining members 62 extend at least a portion of the length of fin 55 , the plurality of retaining members 62 being substantially collinear and substantially parallel with surface 56 . The geometric relationship of the retaining member 62 and the adjacent fin 55 A defines a clip retaining groove 52 which prevents the undesired removal of the clip 40 from groove 52 by moving it upwardly from surface 56 .
There are a number of ways in which retaining members 62 may be formed on pins 54 . In one embodiment, shown in FIG. 5 , heat sink 10 , fins 55 and 55 A and longitudinal groove 52 between adjacent fins 55 and 55 A are extruded from a billet of material by extruding the material along an extrusion axis corresponding to the axis of longitudinal groove 52 . Transverse cuts may be made, by a suitable and known machining or sawing process, in fins 55 and 55 A to provide separate pins 54 and form transverse grooves 53 , oriented substantially perpendicular to grooves 52 . The sawing divides fins 55 and 55 A into a plurality of pins 54 . Since the faces of fins 55 and 55 A on both sides of groove 52 are formed by extrusion rather than cutting, it can be seen that modification of the extrusion dies can readily facilitate the forming of retaining members 62 as part of an extrusion process.
In the embodiment of FIG. 5 , the retaining member 62 extends from a plurality of adjacent fins 55 and 55 A. That embodiment is an example of a heat sink 10 that is adapted to accommodate a clip 40 having a substantially straight central portion 44 .
In various other embodiments, the location of the pins 54 that are selected to have retaining members 62 formed thereon depends on the configuration of the central portion 44 of the clip 40 . As shown in FIGS. 6–11 , any one or more of pins 54 may have retaining members 62 of various shapes for retaining the clip 40 . A plurality of such retaining members 62 need not necessarily be collinearly arranged. Clips 40 having a central portion 44 that may follow an other than straight path across surface 56 of heat sink 10 , can also be accepted in the embodiments discussed below as shown in FIGS. 13–20 .
FIG. 6 is a sectional elevation view taken along section line 6 – 6 ′ of FIG. 5 which illustrates an embodiment of the present invention. The heat sink 10 comprises a plate or base 11 having a surface 70 for engaging a surface of a device to be cooled. Heat sink plate 11 has a plurality of pins 54 that extend upwardly from another surface 56 . The plurality of adjacent, generally parallel, rows of pins 54 define at least one longitudinal groove 52 therebetween which is adapted to retain clip central portion 44 therein. At least one pin 54 has a retaining member 62 extending from the surface of pin 54 into groove 52 .
In the embodiment shown in FIG. 6 , retaining member 62 has wedge shape which, when viewed in cross section, includes a face 72 that slopes downwardly toward surface 56 as the body of retaining member 62 projects inwardly into groove 52 . In the embodiment shown, the shape of retaining member 62 is adapted to allow clip central portion 44 to be introduced into groove 52 from above the retaining member 62 , pass between the retaining member 62 and the adjacent pin 54 , and to subsequently be retained between the retaining member 62 and the surface 56 of heat sink plate 11 . The spacing between retaining member 62 and pin 54 lying across groove 52 from it is selected such that central portion 44 of clip 40 is restrained from being readily removed from groove 52 . In one embodiment, one or both of pins 54 and/or the retaining member 62 is resilient to facilitate the insertion of clip 40 into groove 52 . The resiliency is sufficient to allow retaining member 62 to substantially return to its original shape after introduction of the clip 40 in order to restrict the removal of the clip 40 from the groove 52 .
FIG. 7 is a cross-sectional view of an embodiment showing the use of a rounded retaining member 62 having a rounded surface 74 extending from a side of pin 54 and extending toward an adjacent pin 54 on the other side of groove 52 .
FIG. 8 is a cross-sectional view of another embodiment. At least one pin 54 further comprises a retaining member 62 , resembling in cross-section, a flap extending from a side of the pin 54 . In this embodiment retaining member 62 slopes downwardly and is oriented toward surface 56 and also toward an adjacent pin 54 which defines the other side of groove 52 . It has a partially cut-away lower surface 82 .
FIG. 9 is a cross-sectional view of a further embodiment. One or more pairs of opposing retaining members 62 project inwardly into groove 52 in an opposing relationship from adjacent pins 54 which define opposite sides of groove 52 . The spacing and dimensions of the pair of opposing retaining members 62 and width of groove 52 are selected so as to trap and retain central portion 44 of the clip 40 within the groove 52 . In one embodiment, the pair of opposing retaining members 62 are resilient to allow the insertion of clip 40 , with the pair of opposing retaining members 62 substantially returning to an original shape after the insertion of the clip 40 to prevent unintended removal of the clip 40 from the groove 52 .
In an embodiment of the invention wherein more than one retaining member 62 projects into groove 52 , the retaining members 62 each project from sides of the pins 54 in a co-linear and co-planar relationship, and at a substantially equal height above surface 56 , such as shown with the pair of retaining members 62 shown in FIG. 9 . In that embodiment, the retaining members 62 are located at substantially the same distance above the surface 56 such that the clip 40 may be restrained between retaining member 62 and the second surface 56 . Clip 40 in these embodiments may be retained by the retaining members 62 at any one or more of a number of places along the central portion 44 of the clip 40 , as shown, for example, in FIG. 4 .
In other embodiments of the invention, where more than one retaining member 62 extends into longitudinal groove 52 , the retaining members 62 may not project from sides of the adjacent pins 54 in a co-linear and co-planar relationship, as will be discussed in connection with further embodiments below.
In several of the embodiments discussed above, retaining member 62 projects into the groove 52 a distance sufficient to retain the clip 40 within the groove. This distance is dependent on the width of the groove 52 and the width of the clip 40 . In an embodiment of the invention, the gap between the end of the retaining member 62 and either adjacent retaining member 62 or pin 54 is less than the width of the clip central portion 44 .
In one embodiment of the invention, not shown, wherein the material of clip 40 is in the form of a thin band, clip 40 may be rotated 90 degrees prior to insertion into the groove such that the clip passes beyond the retaining member 62 in an edge-on fashion, and is subsequently rotated 90 degrees to allow retaining member 62 to retain the clip within the groove.
Also in some embodiments of the invention, the projection 62 extends from a side face of pin 54 to form a retention barrier in groove 52 which is sufficiently above surface 56 to define a space 51 , shown in FIG. 12 , in which the central portion 44 is retained. The distance above the surface 56 that the retaining member 62 is located depends, in part, on the height, or the cross sectional diameter, of the clip central portion 44 . In one embodiment, for example, the distance above the surface 56 from which the retaining member 62 extends, as well as the width of the groove 52 , are substantially equal to or slightly greater than either the diameter or the height and width of the central portion 44 . In other embodiments of the invention, it may be advantageous to position the retaining member 62 at a somewhat greater height above surface 56 .
FIG. 10 is a cross-sectional view of an embodiment of a heat sink 10 in which at least one pin 54 has a staked retaining member 62 . The assembly manufacturing method utilized for that embodiment comprises inserting a clip 40 into a groove 52 defined by adjacent rows of pins 54 . The inserted clip 40 is retained by staked retaining member 62 in close proximity to surface 56 of the heat sink 10 . The cross section of central portion 44 of clip 40 and the width of groove 52 are configured to substantially match. In the embodiment of FIG. 10 , a metal working tool such as staking tool 76 is used to deform at least a portion of at least one pin 54 located at one side or wall of the groove 52 into which the clip 40 had previously been placed. When a staking force is applied, tool 76 permanently deforms the pin 54 to form retaining member 62 . A clip retaining space is created between retaining member 62 and the surface 56 to accommodate the portion of clip 40 contained within it so as to retain clip 40 within groove 52 . Other examples of a metal working tool 76 which could be employed include, but are not limited to, chisels or crimping tools.
FIG. 11 is a cross-sectional view of a heat sink constructed in accordance with another embodiment of the method. The method comprises inserting central portion 44 of a clip 40 into a groove 52 that is defined by adjacent rows of pins 54 . Clip 40 is also positioned in close proximity to the surface 56 of the heat sink 10 . The width of groove 52 and the width and cross sectional configuration of the central portion 44 of clip 40 are chosen so that the clip lies in the groove 52 . A metal working tool is used to deform at least a portion of pins 54 on opposite sides of groove 52 into which the clip 40 is placed. The tool works pins 54 to form two cooperating opposed retaining members 62 that provide an upper restraining boundary for a clip receiving space in groove 52 . Retaining members 62 , in cooperative relationship, protrude sufficiently into the groove 52 to retain the clip 40 within groove 52 .
FIG. 12 is a cross-sectional view of a further embodiment. In that embodiment, the method of retaining a clip 40 in a heat sink 10 comprises initially inserting a clip 40 into a groove 52 defined by adjacent rows of pins 54 so that the clip 40 is placed in space 51 in close proximity to the surface 56 of the heat sink 10 . The width of the clip 40 generally matches that of groove 52 . One or more pins 54 adjoining groove 52 are subsequently deformed by bending them together at their end portions which are distal to surface 56 so as to narrow groove 52 above clip 40 to prevent undesired removal of the clip from groove 52 . In one embodiment, the narrowed groove 52 is formed by the squeezing action of a tool, such as a crimping tool, against opposing pins 54 .
The maintenance of proper lateral positioning of heat sink 10 relative to a heat emitting surface of electronic device 20 is also important for proper thermal management. For optimal thermal efficiency, electronic device 20 should remain centered under and in full contact with the heat sink 10 in the aligned arrangement shown in FIG. 2 . Once heat sink 10 is positioned and restrained against electronic device 20 by clip 40 , it retains a potential for shifting or moving laterally by moving longitudinally along the axis central portion 44 of clip 40 in the plane of contact with the electronic device 20 . When heat sink 10 has undergone such lateral movement relative to clip 40 and electronic device 20 it may assume the sort of misalignment shown in FIG. 3 , for example. Mechanical shock which may often be encountered during transportation and in the course of handling, for example, can cause such shifting of the heat sink 10 .
The present invention provides geometric features for restraining the heat sink from moving or shifting laterally in the plane of the device as well as from lifting vertically off of the electronic device upon which it is mounted. For example, FIG. 13 is a top view of an embodiment in a heat sink clip 40 providing longitudinal and transverse lateral restraining as well as vertical restraining characteristics. Clip 40 includes a central portion 44 comprised of a first portion 44 A, a second portion 44 B adjacent to and substantially perpendicular to the first portion 44 A, and a third portion 44 C which is adjacent to and substantially perpendicular to the second portion 44 B and substantially parallel with the first portion 44 A. In this embodiment, the first, second, and third portions 44 A, 44 B and 44 C are substantially coplanar.
In the embodiment of FIG. 13 , heat sink 10 is restricted from moving laterally in the plane of the electronic device by the geometric features provided by bends in the central portion 44 of clip 40 which allow portions of it to be inserted in both longitudinal grooves 52 and transverse grooves 53 that are oriented substantially perpendicular to each other. In the embodiment shown, segment 44 A of clip 40 lies in a first longitudinal groove 52 , segment 44 B, which is substantially perpendicular to segment 44 A, lies in a transverse groove 53 which is perpendicular to longitudinal groove 52 . Finally, segment 44 C lies in a further longitudinal groove 52 that is displaced from first longitudinal groove 52 and is substantially perpendicular to transverse groove 53 . Because of the placement of portions of clip 40 in the perpendicularly oriented grooves 52 and 53 , heat sink 10 is restricted from moving laterally in the plane of the electronic device and the lateral plane of the view shown in FIG. 13 . With the heat sink 10 being restricted from both longitudinal and transverse lateral movement while also being secured from vertical movement perpendicular to the plane of the drawing of FIG. 13 , heat sink 10 will be retained in its desired position relative to the electronic device 20 upon which it is mounted.
FIG. 14 is a top view of another embodiment where a central portion 44 including a first portion 44 A, a second portion 44 B adjacent and perpendicular to the first portion 44 A, a third portion 44 C adjacent and perpendicular to the second portion 44 B and parallel with the first portion 44 A, a fourth portion 44 D adjacent and perpendicular to the third portion 44 C and parallel with the second portion 44 B, and a fifth portion 44 E adjacent and perpendicular to the fourth portion 44 D and substantially collinear with the first portion 44 A. The second, third and fourth portions 44 B, 44 C and 44 D are adapted to provide a geometric feature which places portions of the central portion 44 of clip 40 in perpendicularly intersecting grooves 52 and 53 to secure heat sink 10 against movement laterally and transversely in the plane of the drawing of FIG. 14 . A portion of the central portion of clip 44 can also be said to partially encircle at least one pin 54 , to restrict movement of the heat sink 10 both laterally and transversely in the horizontal plane while also securing it vertically. In the embodiment shown in FIG. 14 , the first, second, third, fourth, and fifth portions 44 A, 44 B, 44 C, 44 D and 44 E are all substantially coplanar and parallel to surface 56 of heat sink 10 .
FIG. 15 relates to another embodiment and shows a lateral restraining of the clip central portion 44 including several bends that combine to comprise a geometric feature or “kink” 92 in the portion oriented to lie in the plane of surface 56 of heat sink 10 . Kink 92 protrudes into perpendicular groove 52 when the distal ends of central portion 44 are inserted into longitudinal groove 53 . Kink 92 is positioned between and restrained by opposing pins 54 with two protrusions 62 flanking geometric feature 92 and thereby substantially preventing lateral movement of the heat sink 10 .
FIG. 16 relates to another embodiment showing of a lateral restraint of clip portion 44 . Central portion 44 has a geometric feature which is a deformation or bulge 94 formed in central portion 44 so that a portion of the geometric feature projects into transverse groove 53 to provide a restraint against longitudinal movement along the axis of central portion 44 . The geometric feature portion 94 restricts transverse longitudinal movement of the heat sink 10 in groove 52 while the central portion 44 of the clip 40 restricts transverse lateral movement of the heat sink 10 relative to clip 40 .
In one embodiment, the heat sink geometric feature 94 which provides lateral restraint is formed by a squeezing action of a crimping tool. The crimping tool permanently flattens a portion of the central portion 44 of the clip 40 to form the bulge 94 which extends transversely into one of the transverse grooves 53 to inhibit longitudinal lateral movement. In one embodiment, deformed portion 94 is formed prior to the insertion of the clip 40 into the longitudinal groove 52 .
In another embodiment, the geometric feature provided by the deformed portion 94 is formed after the insertion of the clip 40 into the groove 52 . In that embodiment, a location on the central portion 44 is chosen where there is an intersection of two perpendicularly intersecting grooves 52 and 53 . In one embodiment, a metal working tool is used to compress the chosen portion of the central portion 44 between a surface of the tool and the heat sink second surface 56 forming the deformed portion 94 . Deformed portion 94 is adapted to extend into the groove 52 and thereby restrain lateral movement of the heat sink 10 .
FIG. 17 shows a detail cross section elevation view of another embodiment. The central portion 44 of the clip 40 bends to provide a geometric feature which is a raised portion 44 C which is parallel to and above surface 56 of heat sink 10 between two non-raised clip portions 44 A and 44 E that are routed closely adjacent to surface 56 . The raised portion 44 C is adapted to cooperate with the retaining members 62 from pins 54 to secure clip portions 44 A and 44 E from vertical movement away from surface 56 . Clip portions 44 A and 44 E are captured between adjacent retaining member 62 and surface 56 and prevent the clip from being vertically withdrawn from the groove 52 . The raised portion 44 C extends above the space between retaining members 62 and the surface 56 . The raised portion 44 C is adapted such that transition portions between segments 44 A and 44 E and raised portion 44 C abuts retaining members 62 to allow them to substantially restrict lateral movement of the heat sink 10 relative to clip central portion 44 .
It is understood that in various embodiments heat sink geometric features can comprise many forms and still cooperate with pins 54 and restrain lateral motion of the heat sink 10 relative to retaining clip 40 . FIG. 18 shows a cut-away view of another embodiment constructed in accordance with the present invention. The central portion 44 of clip 40 has a raised portion 101 comprising an inverted V-shaped kink which engages one or more retaining members 62 from pins 54 on the sides of the groove 52 containing the central portion 44 of clip 40 to prevent substantially all movement of the heat sink 10 relative to clip 40 .
FIG. 19 provides a cut-away view of another embodiment in accordance with the present invention. The central portion 44 bends to a raised portion 103 comprising an inverted U-shaped kink which provides the necessary interference with one or more retaining members 62 to substantially prevent longitudinal movement of the heat sink 10 along the central portion 44 of the clip.
FIG. 20 illustrates, in cross-section, another embodiment in accordance with the present invention. The raised portion 44 C cooperates with two abutting retaining members 62 A and 62 B from a single pin 54 above and below raised portion 44 C so that portion 44 C is captured between the two retaining members 62 A and 62 B. The raised portion 44 C abuts the retaining members 62 A and 62 B to substantially prevent lateral movement of the heat sink 10 relative to along central portion 44 and parallel to surface 56 as well as restraining it vertically. In one embodiment restraining member 62 A is formed after clip 40 is seated in slot 52 and locks it in place. Thus, the geometry features provided by the bends on central portion 44 of the clip 40 restrain it from movement relative to heat sink 10 . Many other interlocking combinations of retaining members 62 and geometrical features of clip 40 will also serve to lock it to heat sink 10 to restrain undesired movement of heat sink 10 relative to the cooled electronic device.
It can also be appreciated, and is within the scope of this invention, that various geometric configurations of the central portion 44 of clip 40 will also restrict undesired movement of the clip 40 relative to the heat sink 10 . For example, in yet another embodiment, not shown, at least a portion of central portion 44 is not aligned with either a groove 52 or a groove 53 but may be placed in a diagonally oriented groove running between pins 54 where it will still contribute to securing heat sink 10 from lateral movement in the plane of the electronic device.
It is to be understood that the above description is intended to be illustrative and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. | 4y
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RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/194,322, filed Aug. 19, 2008, now U.S. Pat. No. 7,668,618, which is a continuation of U.S. patent application Ser. No. 11/714,011, filed Mar. 5, 2007, which is a continuation of U.S. patent application Ser. No. 11/328,955, filed Jan. 9, 2006, which is a continuation of U.S. patent application Ser. No. 10/777,114, filed Feb. 13, 2004, which is a divisional of U.S. patent application Ser. No. 10/215,249, filed Aug. 9, 2002, which claims priority from U.S. Provisional Application No. 60/401,340, filed Aug. 7, 2002, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention generally relates to methods, systems and medium for automatically dispensing and/or packaging of prescriptions and/or prescription orders wherein disparate pharmaceutical packages, e.g., bottles with automatically and/or manually dispensed pills, packages with pharmaceutical products, literature packs that are optionally patient specific, etc., are automatically dispensed and/or combined into packages. The present invention may be used for mail order pharmacies, wholesalers and/or central fill dealers for subsequent distribution or sale including a retailer.
BACKGROUND OF THE INVENTION
In mail service pharmacies and large retail pharmacies, prescription drugs are dispensed in a high volume. For such services, it is known to use an automatic pill dispensing system to carry out the dispensing of the prescription drugs automatically at a rapid rate and to label pill containers which can then be provided to the patient for whom the prescriptions were written.
A known automatic pill dispensing system is described in U.S. Pat. No. 5,771,657 issued to Lasher et al., which is incorporated herein by reference. In the patent, as shown in the schematic illustration of FIG. 1A , orders (e.g., orders to fill prescriptions) are received by a host computer 9 which forwards the orders to a distributed computer system including a central computer called Pharmacy Automation Controller 10 (PAC). PAC maintains an order file of the information about each prescription to be filled in an order including all of the information needed to fill each prescription, prepare a prescription label for each prescription and the information to print literature to go in a shipping container with the prescription or prescriptions. PAC updates the order file to maintain a record of the current status of each prescription being filled as it progresses through the automated system.
PAC 10 controls a set of PAL stations 14 which print prescription bottle labels, apply the prescriptions to prescription bottles, and load the labeled bottles onto bottle carriers, a carrier conveyer system 21 which carries the bottle carriers to different parts of the system, automatic drug dispensing machines 23 which dispense tablets or capsules into the prescription bottles in the bottle carriers as they are carried by the conveyer system 21 , bottle cappers 25 which apply caps to the bottles, and OCP stations 29 at which the bottles are unloaded from the carriers and placed in the shipping containers corresponding to the patient orders. The conveyer system 21 carries the bottles in the carriers from the PAL stations through the automatic drug dispensing machines 23 to the bottle cappers 25 and then from the bottle cappers to the OCP stations 29 . The conveyer system 21 also carries the empty carriers back to the PAL stations 14 . The OCP stations each also have a literature dispensing mechanism, which inserts printed literature into each shipping container with the filled and capped prescription bottles. PAC 10 controls literature printers 31 which print literature for each prescription order and enclose the literature for each prescription order in an envelope, print a bar code that shows through a window in the envelope identifying the prescription order, and then place each envelope on a literature conveyer 34 which carries the envelope from the literature printers 31 to the OCP stations 29 .
As shown in FIG. 1B , bottles to be automatically filled with the prescription drugs are introduced to the automated system by hoppers 37 which receive the bottles in bulk form and automatically feed the bottles to unscramblers 39 . One of the hoppers 37 and one of the unscramblers 39 will be for large bottles of 160 cc. and the remaining hoppers and unscramblers will be for small bottles of 110 cc. The small bottle size can accommodate a majority of the automatically filled prescriptions. The large bottles are large enough for 91 percent of the prescriptions and are used to fill the prescriptions in that 91 percent which are too large for the small bottles. The remaining 9 percent of the prescriptions which are too large for the large bottles are filled by using multiple bottles. A large bottle and a small bottle will contain a volume required for 97.5 percent of the automatically filled prescriptions. In the unscramblers, the bottles are singulated and oriented so that the bottle opening first faces downward. The bottles are then righted and directed to PAL stations 14 on bottle conveyers 41 and 43 , one for large bottles and one for small bottles.
In the above described conventional system, bottles from one order and corresponding literature are combined into one package. However, many orders include prescriptions for non-pill pharmaceutical products. For example, prescriptions may include liquid pharmaceutical packages, boxes and/or pre-packaged bulk bottles. In addition, as noted above, when prescriptions are filled and mailed to patients, the mail package may include literatures relating to the drugs in the package. The conventional systems are not configured to dispense and combine automatically the above-listed disparate pharmaceutical products into packages.
SUMMARY OF THE INVENTION
Computer-assisted methods, systems and mediums of the present invention overcome, among others, the shortcomings of the above-described conventional systems.
The present invention includes a system for filling at least one order that includes one or more prescriptions. The system includes at least one order consolidation station configured to receive at least one bottle containing pills individually counted and/or the at least one package containing pharmaceutical products without having been pre-designated for the at least one order when the at least one package was created. The at least one bottle is specifically designated for the at least one order, and the at least one order includes at least one prescription for the at least one package. The order consolidation station is further configured to combine automatically the received at least one bottle and/or the at least one package to send the combined the at least one bottle and/or the at least one package to a patient for whom the at least one order was written, thereby filling the at least one prescription.
The at least one order consolidation station can be further configured to receive at least one literature pack containing printed literature relating to the at least one order and configured to combine the at least one literature pack with the combined at least one bottle and/or the at least one package.
The system may also include a package storage device having an array of locations and configured to store the at least one package into one of the array of locations. The system can also include a package dispenser configured to identify the one of the array of locations, pick the at least one package from the one of the array of locations and send the at least one package to the order consolidation station.
The system may also include a package storage device having an array of locations and configured to store a plurality of packages into the array of locations and store the at least one package into one of the array of locations. The system can include a package dispenser configured to identify the one of the array of locations, pick the at least one package from the one of the array of locations and send the at least one package to the order consolidation station.
The package dispenser can include a package label printer to print at least one label for the at least one package. The label is printed with patient specific information including instructions by a prescribing doctor to the patient. The package dispenser may further include a label folder and/or manipulator configured to fold and/or manipulate the at least one label into a wrapped label having a sufficiently small footprint to be affixed on the at least one package. The package dispenser can also include an error detection system configured to detect and read the label affixed on the at least one package and configured to reject the at least one package and the label if an incorrect label is affixed thereto.
The system can also include a bottle storage device having an array of locations and configured to store a plurality of bottles into one of the array of locations, and a bottle dispenser configured to identify the one of the array of locations and send the at least one bottle from the one of the array of the locations to the order consolidation station.
The bottle dispenser can also comprise a metal detector configured to detect a present of a metallic substance in the at least one bottle. The bottle dispenser can be further configured to reject the at least one bottle if a metallic substance is detected therein. The bottle dispenser can also include a bottle magazine to receive the at least one bottle belonging to the one of at least one order. The bottle magazine is disposed and configured to release the received at least one bottle into the bag.
In addition, the system can also include a bagger configured to open a bag to receive the at least one bottle and/or the at least one package into the bag. The bagger can also include an address label or internal control label printer configured to print an address of the patient. The bagger can be further configured to affix the address label or internal control label on the bag before the bag is opened.
The present invention also includes a system for filling at least one order. The system may include a bottle handling station configured to store and dispense at least one bottle containing pills individually counted. The at least one bottle is specifically designated for the at least one order. The system can also include a package handling station configured to store and dispense at least one package containing pharmaceutical products without having been pre-designated for the at least one order when the at least one package was created. The at least one order includes at least one prescription for the at least one package. The system can further include an order consolidation station configured to combine the received at least one bottle and/or the at least one package to send the received at least one bottle and the at least one package to a patient for whom the at least one order was written, to thereby fill the one of at least one order and/or prescription.
The system may also include a literature handling station configured to store and dispense at least one literature pack containing printed literature relating to the at least one order. The order consolidation station can be further configured to receive the at least one literature pack and combine the at least one literature pack with the received at least one bottle and/or the at least one package.
The present invention also provides a system for filling a plurality of orders. The system comprises a bottle handling station configured to store a plurality of bottles each containing pills individually counted. Each bottle is specifically designated for one of the plurality of orders. The system can also include a literature handling station configured to store a plurality of literature packs each containing printed literature relating to one of the plurality of orders and configured to determine a sequence in which the literature packs are stored with respect to corresponding orders. The system may also include a computer system configured to monitor the bottle handling and literature handling stations and configured to cause the bottle handling station to dispense the bottles in the sequence in which the literature packs are stored with respect to corresponding orders and/or prescriptions. The system may further include an order consolidation station configured to receive the bottles and the literature packs in the sequence in which the literature packs are stored with respect to corresponding orders and/or prescriptions and configured to combine the bottles and the literature packs belonging to one of the plurality of orders.
The system may also include a package handling station configured to store a plurality of packages containing pharmaceutical products without having been designated for any of the plurality of orders when the plurality of packages is created. The computer system is further configured to monitor the package handling station and cause the package handling station to dispense the packages in the sequence in which the literature packs are stored with respect to corresponding orders. The order consolidation station can be further configured to receive the packages in the sequence in which the literature packs are stored with respect to corresponding orders and/or prescriptions and configured to combine the packages belonging to the one of the plurality of orders with the combined bottles and literature packs.
The computer system can also be configured to detect an error when the bottles are not received by the order consolidation station in the sequence in which the literature packs are stored. The computer system can also be configured to detect an error when the packages are not received by the order consolidation station in the sequence in which the literature packs are stored.
The present invention also provides a method for filling at least one order. The method can include the step of receiving at least one bottle containing pills individually counted and/or the at least one package containing pharmaceutical products without having been pre-designated for the at least one order when the at least one package was created. The at least one bottle is specifically designated for the at least one order, and the at least one order includes at least one prescription for the at least one package. The method may also include the step of automatically combining the received at least one bottle and/or the at least one package to send the at least one bottle and/or the at least one package to a patient for whom the at least one order was written, to thereby fill the one of at least one order.
The method may also include the step of receiving at least one literature pack containing printed literature relating to the at least one order and configured to combine the at least one literature pack with the received at least one bottle and/or the at least one package.
The method can also include the steps of storing the at least one package into one of an array of locations of a package storage device, identifying the one of the array of locations, and picking the at least one package from the one of the array of locations. The method may further include the step of printing at least one label for the at least one package. The label is printed with patient specific information including instructions by a prescribing doctor to the patient. The method can also include the step of folding, configuring or manipulating the at least one label into a sufficiently small footprint to be affixed on the at least one package.
The method may also include the steps of detecting and reading the label affixed on the at least one package, and rejecting the at least one package and the label if an incorrect label is affixed thereto. The method can also include the steps of storing the at least one bottle into one of an array of locations in a bottle storage device, and identifying the one of the array of locations. The method may further comprise the steps of detecting the presence of a metallic substance in the at least one bottle and rejecting the at least one bottle if a metallic substance is detected therein.
The method may also include the step of opening a bag to receive the at least one bottle and/or the at least one package into the bag. The method may also include the steps of printing an address of the patient and affixing the address label on the bag before the bag is opened.
The present invention also provides a method for filling at least one order. The method comprises the step of storing and dispensing at least one bottle containing pills individually counted. The at least one bottle is specifically designated for the at least one order. The method may also include the step of storing and dispensing at least one package containing pharmaceutical products without having been designated for any of the at least one order when the at least one package was created. The at least one order includes at least one prescription for the at least one package. The method can also include the step of combining the received at least one bottle and/or the at least one package to send directly or indirectly using a variety of means, for example, through a retailer, wholesaler, and/or central fill, the at least one bottle and/or the at least one package to a patient for whom the at least one order was written, to thereby fill the one of at least one order.
The method may also include the steps of storing and dispensing at least one literature pack containing printed literature relating to the at least one order and receiving the at least one literature pack and combining the at least one literature pack with the received at least one bottle and/or the at least one package.
The present invention also provides a system for filling at least one order. The system includes at least one order consolidation means for receiving at least one bottle containing pills individually counted and/or the at least one package containing pharmaceutical products without having been pre-designated for the at least one order when the at least one package was created. The at least one bottle is specifically designated for the at least one order, and the at least one order includes at least one prescription for the at least one package. The order consolidation means can be further configured for automatically combining the received at least one bottle and/or the at least one package into a bag to be sent to a patient for whom the at least one order was written, to thereby fill the one of at least one order.
The order consolidation means can be further configured for receiving at least one literature pack containing printed literature relating to the at least one order and combining the at least one literature pack with the received at least one bottle and at least one package.
The system may also include a package storage means, having an array of locations, for storing the at least one package into one of the array of locations and a package dispense means for identifying the one of the array of locations, picking the at least one package from the one of the array of locations and sending the at least one package to the order consolidation means. The package dispense means can also include a package label printer to print at least one label for the at least one package. The label is printed with patient specific information including instructions by a prescribing doctor to the patient. The package dispense means can further include a label folder configured to fold the at least one configured or manipulated label having a sufficiently small footprint to be affixed on the at least one package.
The package dispense means can further include an error detection system configured to detect and read the label affixed on the at least one package and discard the at least one package and the label if an incorrect label is affixed thereto.
The system can also include a bottle storage means, having an array of locations, for storing the at least one bottle into one of the array of locations and a bottle dispense means for identifying the one of the array of locations and sending the at least one bottle from the one of the array of the locations to the order consolidation means.
The bottle dispense means can include a metal detector means for detecting the presence of a metallic substance in the at least one bottle. The bottle dispense means may be further configured for rejecting the at least one bottle if a metallic substance is detected therein.
The bottle dispense means can include a bottle magazine means for receiving the at least one bottle belonging to the one of at least one order. The bottle magazine means is disposed and configured to release all received at least one bottle into the bag.
The system may also include a bagger means for opening the bag to receive the at least one bottle and at least one package into the bag. The bagger means may include an address label printer means for printing an address of the patient. The bagger means can be further configured for affixing the address label on the bag before the bag is opened.
The present invention may also provide a system for filling at least one order. The system may include a bottle handling means for storing and dispensing at least one bottle containing pills individually counted. The at least one bottle is specifically designated for the at least one order. The system may also include a package handling means for storing and dispensing at least one package containing pharmaceutical products without having been designated for any of the at least one order when the at least one package was created. The at least one order may include at least one prescription for the at least one package. The system may also include an order consolidation means for combining the received at least one bottle and at least one package into a bag to be sent to a patient for whom the at least one order was written, to thereby fill the one of at least one order.
The system may also include a literature handling means for storing and dispensing at least one literature pack containing printed literature relating to the at least one order. The order consolidation means can be further configured to receive the at least one literature pack and combining the at least one literature pack with the received at least one bottle and/or the at least one package.
The system can also provide a system for filling a plurality of orders. The system can include a bottle handling means for storing a plurality of bottles each containing pills individually counted. Each bottle and/or bottles is/are specifically designated for one of the plurality of orders. The system may also include a literature handling means for storing a plurality of literature packs each containing printed literature relating to one of the plurality of orders and for determining a sequence in which the literature packs are stored with respect to corresponding orders. The system may also include a computer system configured to monitor the bottle handling and literature handling means and configured to cause the bottle handling means to dispense the bottles in the sequence in which the literature packs are stored with respect to corresponding orders. The system may also include an order consolidation means for receiving the bottles and the literature packs in the sequence in which the literature packs are stored with respect to corresponding orders and for combining the bottles and the literature packs belonging to one of the plurality of orders.
The system may further include a package handling means for storing a plurality of packages containing pharmaceutical products without having been designated for any of the plurality of orders when the plurality of packages is created. The computer system can be further configured to monitor the package handling means and cause the package handling means to dispense the packages in the sequence in which the literature packs are stored with respect to corresponding orders. The order consolidation means can be further configured for receiving the packages in the sequence in which the literature packs are stored with respect to corresponding orders and configured for combining the packages belonging to the one of the plurality of orders with the received bottles and literature packs.
The present invention may also include a bottle storage apparatus. The device comprising a plurality of storage locations, each storage location, for example, having a top side and a bottom side, and a pin disposed on the bottom side of each of the plurality of storage locations, the pin having an open position and a closed position. Other storage location configurations may alternatively be used. The device also comprises a first gantry crane having a means for picking up a bottle and feeding the bottle to one of the plurality of storage locations via the top side thereof. The bottle is held by the one of the plurality of storage locations, for example, when the pin is in the closed position. The system may also include a second gantry crane having a means for moving, for example, one of the pins from the closed position to the open position. The system may also include a computer system coupled to the first and second loading devices (e.g., gantry cranes) and capable of identifying a location of each storage location. The computer system can be configured to instruct the first loading device to pick up one or more bottles belonging to a order and to feed the one or more bottles to one or more of the plurality of storage locations. The computer system can be further configured to instruct the second gantry crane to, for example, move the pins of the one or more of the plurality of storage locations from the close position to the open position when all of the one or more bottles belonging to the order has been fed to the one or more of the plurality of storage locations.
The plurality of storage locations forms a table. The first gantry crane is disposed on a top side of the table and the second gantry crane, robot arm and/or other standard mechanism is disposed on a bottom side of the table.
The invention of present application provides a system of filling a plurality of orders. A pinch belt including a plurality of locations each of which is capable of carrying a pack of printed material belong to a order. A bottle storage table includes a plurality of storage locations to store at least one bottle belonging to the order. A first conveyor line is located to receive the at least one bottle from the bottle storage table and having a moving surface to move the at least one bottle received from the bottle storage table. The system may also include a means for receiving and holding the at least one bottle and a plurality of shelf locations, each shelf location containing at least one package belonging to the order. The system may also include a robot having an end effector to pick the at least one package and a means to release the at least one package and a second conveyor line having a moving surface to move the at least one package received from the robot. The system can also include a robot arm or other standard mechanism having an end effector to pick up the at least one package and a bagger having a set of arms to open and hold a bag. The system can further include a computer system configured to instruct the pinch belt to convey at least one pack of printed material and discharge the at least one pack into the bag, instruct the bottle storage table to release the at least one bottle, instruct the first conveyor line to move the at least one bottle and dispose the at least one bottle into the bag, instruct the robot to pick up the at least one package and release the at least one package onto the second conveyor line, instruct the second conveyor line to move the at least one package, and instruct the robot arm to pick up and dispose the at least one package into the bag.
There has thus been outlined, rather broadly, the 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.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, 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.
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.
Other features of the present invention will be evident to those of ordinary skill, particularly upon consideration of the following detailed description of the preferred embodiments.
Notations and Nomenclature
The detailed descriptions which follow may be presented in terms of program procedures executed on computing or processing systems such as, for example, a stand-alone computing machine, a computer or network of computers. These procedural descriptions and representations are the means used by those skilled in the art to most effectively convey the substance of their work to others skilled in the art.
A procedure is here, and generally, conceived to be a sequence of steps leading to a desired result. These steps are those that may require physical manipulations of physical quantities (e.g., combining various pharmaceutical products into packages). Usually, though not necessarily, these quantities take the form of electrical, optical or magnetic signals capable of being stored, transferred, combined, compared and otherwise manipulated. It proves convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like. It should be noted, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities.
Further, the manipulations performed are often referred to in terms, such as adding or comparing, which are commonly associated with mental operations performed by a human operator. No such capability of a human operator is necessary, or desirable in most cases, in any of the operations described herein which form part of the present invention; the operations are machine operations. Useful machines for performing the operation of the present invention include general purpose digital computers or similar devices, including, but not limited to, microprocessors.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description of the present application showing various distinctive features may be best understood when the detailed description is read in reference to the appended drawing in which:
FIGS. 1A-1B are diagrams illustrating a conventional automated pill dispenser;
FIG. 2 is a diagram illustrating various components of embodiments of the present invention;
FIG. 3 is a diagram illustrating an initial set of determinations that a host computer is configured to make for embodiments of the present invention;
FIG. 4 is a diagram illustrating various steps performed by embodiments of the present invention;
FIG. 5 is a diagram illustrating various steps performed by embodiments of the present invention;
FIG. 6 is a diagram illustrating various steps performed by embodiments of the present invention;
FIG. 7 is a diagram illustrating various steps performed by embodiments of the present invention;
FIG. 8 is a diagram illustrating various example components of embodiments of the present invention;
FIGS. 9A-9C are diagrams illustrating an example bottle storage table of embodiments of the present invention;
FIG. 10 is a diagram illustrating a tube structure of the example bottle storage table of embodiments of the present invention;
FIG. 11 is a diagram illustrating an example storage device and dispenser for packages of embodiments of the present invention;
FIG. 12 is a diagram illustrating an example consolidation station and its associated components of embodiments of the present invention;
FIG. 13 is a diagram illustrating the steps performed by the consolidation station and its associated components of embodiments of the present invention;
FIG. 14 is a diagram illustrating an example package scanning and labeling station of embodiments of the present invention;
FIG. 15A-15E are diagrams of an example consolidation station and its associated components of embodiments of the present invention;
FIG. 16 is a schematic diagram of example bagger and dispenser for packages of embodiments of the present invention;
FIG. 17 is a schematic diagram of an example bagger and dispenser for bottles of embodiments of the present invention;
FIG. 18 is a diagram illustrating a label for a package of embodiments of the present invention;
FIG. 19 is a diagram illustrating the steps performed and dispenser for packages and its local computer of embodiments of the present invention;
FIG. 20 is diagram illustrating an example bagger of embodiments of the present invention;
FIG. 21 is a diagram illustrating example control processes for embodiments of the present invention;
FIGS. 22-26 are diagrams illustrating example control schemes for literature packs of embodiments of the present invention;
FIG. 27 is a diagram illustrating an example computer network scheme for embodiments of the present invention;
FIG. 28 is a block diagram representation of an example embodiment of computer network(s) implementing embodiments of the present invention;
FIG. 29 illustrates a computer that can be used in implementing embodiments of the present invention;
FIG. 30 is a block diagram of internal hardware of the example computer shown in FIG. 29 ; and
FIG. 31 illustrates one example of a memory medium which may be used for storing computer programs of embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference now will be made in detail to the presently preferred embodiments of the invention. Such embodiments are provided by way of explanation of the invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made.
For example, features illustrated or described as part of one embodiment can be used on other embodiments to yield a still further embodiment. Additionally, certain features may be interchanged with similar devices or features not mentioned yet which perform the same or similar functions. It is therefore intended that such modifications and variations are included within the totality of the present invention.
Embodiments of the present invention are directed to dispensing orders that include various pharmaceutical products (e.g., bottles that contain counted pills, packages that include liquid or pre-packaged pharmaceutical products and/or patient specific literatures). In embodiments of the present invention pills also refer to tablets, capsules and other similar terms known in the art. FIG. 2 is a schematic diagram illustrating various components that can be used in embodiments of the present invention. In particular, the components include a storage device for packages 203 , dispenser for the packages 205 , storage device for bottles filled with counted pills 209 , dispenser for the bottled with counted pills 207 , storage device for patient specific literatures 211 , dispenser for the patient specific literatures 213 , consolidation station 215 and host computer 201 . Embodiments of the present invention can also include one or more local computers (Not shown in FIG. 2 ). For instance, each of the components listed above (e.g., the storage device for packages 203 , dispenser for the packages 205 , storage device for bottles 209 , dispenser for bottles 207 , storage device for literature packs 211 and dispenser for literature packs 213 ) can be connected to one or more local computers. The local computers in turn are connected to the host computer 201 . In this way, the host computer 201 and local computers are configured to control the various components of the present invention as described below.
A local computer can also function with a standard Programmable Logic Controller (PLC). A PLC typically includes an I/O card to turn on/off a device. Accordingly, when a component is to be controlled by turning it on/off, a PLC can be used. When a large quantity of data is to be exchanged, a local computer can be used.
The storage device for packages 203 stores packages that contain pharmaceutical products. For example, one set of packages may contain a predetermined number of tablets (e.g., 500 tablets) of a certain drug (e.g., Allegra). Another set of example packages may include liquid pharmaceutical products. The packages can be made by original producers of drugs (e.g., Hoechst Marion Roussel). The packages can also be bulk bottles that are filled by any one of many automated (e.g., the ADDS) or manual methods known in the art. These packages can then be shelved so that their locations can be automatically identified. In turn, the dispenser for the packages 205 is configured to automatically identify the location of any package with a certain type of drug, dosage and/or quantity and configured to pick one or more packages from the identified location. In other words, a package contains a pharmaceutical product without having been pre-designated for any specific order when the package was created.
In operation, the command to locate and pick one or more packages is received from the host computer 201 . The dispenser for packages can also be connected to its own local computer to perform the necessary functions to locate and pick one or more packages in accordance with the command from the host computer 201 . It should be noted that the packages stored in the storage device for packages 203 are not designated for any specific patient. In other words, any package can be picked to fill a order of a patient as long as the type of drug, dosage and/or quantity are matched with the order.
Embodiments of the present invention can also include a standard sensor or a standard counter to indicate when a specific type of package is out of stock in the storage device for packages 203 . These sensors or counters can be present at each location (or a substantial number of them). The signals from the sensors or counters can be communicated to, for example, the host computer 201 via the local computer. In turn, the host computer 201 can notify an operator or system to replenish the specific packages and/or stop the process of filling orders that require the specific type of package that are out of stock in the storage device for packages 203 . In addition, or optionally, the host computer 201 can send a query to the storage device for packages 203 regarding whether a certain number of certain packages are available to be dispensed. In response, the storage device for packages 203 , or in combination with its local computer, can send a response based on information from the sensors and/or counters. Alternatively, sensors may be placed on the robot arm or picking device to provide the similar functionality. In yet another alternative, sensors are not utilized and the system keeps logical control by knowing how many packages have been placed in a channel and how many packages have been removed from the channel.
The dispenser for bottles 207 is configured to receive bottles that contain specific number (e.g., 1-500 or more) of pills for a specific order. For example, one bottle may include 350 tablets of one type of drug for patient A, while another bottle may include 600 tablets of another type of drug for patient B. The bottles can be filled by any automatic dispensing mechanisms known in the art (e.g., the system shown in U.S. Pat. No. 5,771,657). The bottles can also be filled by a person (e.g., a pharmacist) manually counting pills.
If an automatic dispensing system is used, the host computer 201 sends commands to fill bottles with certain number of pills for a certain type of drug. Once they are filled, the bottles are stored in the storage device for bottles 209 . In a similar fashion, in a manual system, the dispensing person would receive an instruction to count certain number of tablets for a certain type of drug. The person fills bottles according to the instructions and forwards the bottles to the storage device for bottles 209 .
Once the storage device for bottles 209 receives all the bottles necessary to fill an order, the storage device for bottles 209 or in connection with its local computer sends a message to the host computer 201 indicating that the bottle portion of the order has been filled. For example, an order to fill an order may require 1450 pills of a certain type of drug. In this example, the storage device for packages 203 may already have two packages each with 500 pills of the drug. If so, one bottle with 450 pills of the drug is necessary to fill the bottle portion of the order. (If one bottle cannot receive all 450 pills then more than one bottle would become necessary to provide the 450 pills).
Now turning to describe the storage device for literature packs 211 , contains literatures to be packaged with specific orders. For example, a set of literature packs for one order may include information relating to each of the prescribed drugs, how often each drug must be taken, billing information, special instructions from the prescribing doctor, insurance information, refilling information and/or general information, for example health or notification of other services. The set of literature packs is then packaged per order and collected in the storage device for literature packs 211 . Once the necessary literature packs are created, the storage device for literature packs 211 , or in combination with its local computer, can notify the host computer 201 that the literature pack has been printed.
Upon receiving various information from the storage device for packages 203 , storage device for bottles 209 and storage device for literature packs 211 , the host computer 201 then sends instructions to the dispenser for the packages 205 , dispenser for bottles 207 and dispenser for literature packs 213 , or to their local computers, to dispense necessary bottle(s), package(s) and literature pack(s) to fill one or more orders. The dispensed bottle(s), package(s) and literature pack(s) are then consolidated by the consolidation station 215 and then sent, distributed or mailed out directly or indirectly to patients associated with the orders. The interactions between the consolidation station 215 and the various components illustrated in FIG. 2 are further described in detail below.
More specifically, FIG. 3 illustrates example steps taken by the host computer 201 in combination with the local computers and/or the various components. The host computer 201 first receives a request to fill a order. In response, the host computer 201 creates an order number and determines whether the order contains an order that requires bottles to be filled by counting individual tablets and whether the order contains an order that requires packages from the storage device for bottles 209 . Depending upon the answers to the above two questions the host computer 201 conducts a number of different sets of steps.
If the order requires both one or more bottles from the storage device for bottles 209 and one or more packages from the storage device for packages 203 , then the steps shown in FIG. 4 are executed. If the order requires one or more bottles from the storage device for bottles 209 but does not require any packages from the storage device for packages 203 , then the steps shown in FIG. 5 are executed. If the order requires no bottles from the storage device for bottles 209 but requires one or more packages from storage device for packages 203 , then the steps shown in FIG. 6 are executed. If the order requires no bottles from the storage device for bottles 209 and no packages from the storage device for packages 203 , then the steps shown in FIG. 7 are executed.
Referring to FIG. 4 , there is shown a set of steps that can be performed by the host computer 201 , in combination with various other components illustrated in FIG. 2 and their local computers when both bottle(s) from the storage device for bottles 209 and package(s) from the storage device for packages 203 are required to be filled for a order. In the manual counting system, an instruction can be printed or shown on an operator's computer monitor to count and fill a specific drug. In the automated system, the host computer 201 can send a set of commands to cause a drug dispenser to count and fill a specific drug, thereby performing the step of automatically dispensing tablets into bottles (step 401 ).
Whether the manual system and/or the automated system is used, label(s) are prepared and printed to be affixed on the surface of the bottles, thereby performing the step of associating order specific information with the bottles (step 403 ). The label can be affixed on the caps, sides and/or bottom sides of the bottles as long as they can be located in the later processing steps. The printed labels can contain various information. At minimum, it can contain machine readable (e.g., barcodes) and/or human readable codes/texts so the bottles can be matched to the order numbers in the later processing steps. In addition, the labels can contain information relating to the patient, the drug or any other pertinent information or any combination thereof. One label or a set of labels can be printed and affixed on each bottle. The labels can be printed before, after and/or while the bottles are filled. If the labels are printed before or after the bottles are filled, then printed labels or the bottles need to be queued to be matched with correct bottles or labels, respectively. It should be noted that the information can be printed on the bottles directly and that the information can be alternatively contained in a unique identifier (e.g., radio tags).
As noted above, in filling some orders, more than one bottle may be required. Accordingly, the host computer 201 and/or the local computer determines how many bottles are required. If more than one bottle is required, a notification that the bottles are filled is sent after all the bottles have been filled (steps 405 , 407 , and 409 ). If only one bottle is required, a notification is sent as soon as the one bottle is filled (steps 405 and 409 ). The bottles with the labels affixed thereon are then sent and stored in the storage device for bottles 209 . Upon receiving the notification, the host computer 201 and/or a local computer causes corresponding literature pack(s) to be printed (step 411 ). In some embodiments before, after and/or while the bottles are filled, the host computer 201 can cause literature pack(s) relating to the order to be printed. Once the literature pack(s) is printed, they can be sent and stored in the storage device for literature packs 211 .
When the printing literature packs step is completed, a notification is sent to the host computer 201 and/or local computer (step 415 ). Upon receiving the notification that the literature packs have been printed, the host computer 201 and/or local computers cause packages required to fill the order to be automatically dispensed from dispenser for the packages 205 (steps 415 ).
With respect to the packages in the storage device for packages 203 , as noted above, the host computer 201 can determine if the necessary packages are stocked in the storage device for packages 203 . If not, then the host computer 201 can cause the necessary packages to be stocked in the storage device for packages 203 (either manually or automatically).
Although the steps illustrated in FIG. 4 can be performed in a sequence, such a sequence is not required in the present invention. For instance, the step of printing literature packs (step 411 ) can be performed before other steps. In another example, the step of filling bottles (steps 405 , 407 , 409 ) can be performed before other steps. It should be noted that determining which of the steps are performed before other steps can be an engineering design choice. In one instance, if the step of printing literature packs takes the longest time compared with other steps, then the printing step may be started the first. In another instance, if the step of filling bottle(s) takes the longest time compared with other steps, then the filling bottle(s) step may be started the first before other steps.
Now turning back to FIG. 4 , once the host computer 201 receives notifications from the storage device for literature packs 211 , storage device for bottles 209 and storage device for packages 203 that the respective literature(s), bottle(s) and package(s) for a order have been received and stored, then the host computer 201 causes the dispenser for literature packs 213 , dispenser for bottles 207 and dispenser for the packages 205 to dispense and send the items to the consolidation station 215 . The consolidation station 215 , upon receiving the literature(s), bottle(s) and package(s), combines them into one or more bags (step 417 ). If the received packages completely fill a order, then the one or more bags can be sealed and a mailing label or internal control label can be affixed on each bag. If the received packages do not completely fill a order and require more packages to be put into the one or more bags, then those bags are sent over to a station where the remaining packages can be put into the bags or joined to the order.
In some embodiments of the present invention, the dispenser for literature packs 213 , dispenser for bottles 207 and dispenser for the packages 205 can be configured to dispense literature(s), bottle(s) and package(s) to fill one order at a time. In particular, the dispenser for literature packs 213 dispenses one set of literature(s) to fill one order for one patient, the dispenser for bottles 207 dispenses one set of bottles to fill the one order, the dispenser for the packages 205 dispenses one set of packages to fill the one order. In such embodiments, the consolidation station 215 is configured to receive the packages and put them into bags to be mailed or sent over to the next process stations.
In other embodiments of the present invention more than one (e.g., many tens of thousands) of orders can be filled continuously. In such embodiments, a batch of literature packs for a number of orders can be printed and queued in the storage device for literature packs 211 . In this embodiment, the sequence in which the literature packs are queued can be used in determining which order's bottle(s) and package(s) are filled first. For instance, assume the literature packs queued in the dispenser for literature packs 213 are in the following sequence: Order A, Order B, Order C and so on. If so, the host computer 201 causes the bottle(s) for Order A be filled first. As soon as the bottle(s) are filled, the host computer 201 then can cause the dispenser for bottles 207 to dispense the bottle(s) for Order A to be dispensed and sent over to consolidation station 215 , while causing the dispenser for literature packs 213 to dispense and send the literature pack for Order A be dispensed and sent over to the consolidation station 215 . The host computer 201 also causes the same for the packages to dispensed by the dispenser for the packages 205 . The consolidation station 215 then combines the received packages.
In yet other embodiments of the present invention, a batch of bottles for a number of orders can be queued in the dispenser for bottles 207 . In such embodiments, the sequence in which the bottles are queued can be used in determining which order's literature(s) and package(s) are filled first in a similar manner as described above. Embodiments in which a batch of packages in the dispenser for the packages 205 that determines the sequence of dispensing are also contemplated within this invention.
Referring to FIG. 5 , there is shown a set of steps that can be performed by the host computer 201 , in combination with various other devices/components illustrated in FIG. 2 and their local computers when bottles from the storage device for bottles 209 but no package(s) from the storage device for packages 203 are required to fill orders. As shown in FIG. 5 , most of the steps are similar to the steps shown in FIG. 4 but no steps to dispense packages are included.
In FIG. 6 , there is shown a set of steps that can be performed by the host computer 201 , in combination with various other devices/components illustrated in FIG. 2 and their local computers when package(s) from the storage device for packages 203 but no bottle from the storage device for bottles 209 are required to be filled. As shown in FIG. 6 , most of the steps are similar to the steps shown in FIG. 4 but no steps to dispense bottles are included.
Referring to FIG. 7 , there is shown a set of steps that can be performed by the host computer 201 , in combination with various other devices/components illustrated in FIG. 2 and their local computers when only manually picked packages are required to fill orders. Examples of manually picked packages are oddly shaped boxes, large boxes, products packaged in plastic bags, manual assistance, etc. These packages cannot be stocked in the storage device for packages 203 because of their odd shapes or because of possible failures. As shown in FIG. 7 , literature packs for the orders are printed (step 701 ). After one or a batch of the literature packs have been printed, the host computer 201 is notified that all packs have been printed (steps 703 and 705 ). Upon receiving the notification, the host computer 201 sends a set of instructions to an operator to fill the orders by manually counting the required packages. It should be noted that the steps of manually picking packages can also be included in the steps illustrated in FIGS. 4-6 .
Now turning to describe details of the various components shown in FIG. 2 , FIG. 8 illustrates an overall plant layout of an example embodiment of the present invention. In the example embodiment, the storage device for literature packs 211 is a dispatch unit 801 , the dispenser for literature packs 213 is a conveyor belt 803 (e.g., a pinch belt), the storage device for bottles 209 is a bottle storage table 805 , the dispenser for bottles 207 is a mechanism that releases bottles queued in the bottle storage table 805 , the storage device for packages 203 is a bank of shelves 807 , the dispenser for the packages 205 is a standard picking robot 809 , and the consolidation station 215 is an order consolidation station 811 including a bagger 813 .
These various components can be provided in an assembly line configuration. As shown in FIG. 8 , three sets of each component/system can be provided. For instance, the order consolidation station 813 receives literature packs from the dispatch unit 801 via the conveyor belt 803 , receives bottles from the bottle storage table 805 and receives the packages from the picking robot 809 . The dispatch unit 801 includes a scanner to read the barcodes on the literature packs. The dispatch unit 801 then mounts the literature packs on the belt 803 . It should be noted that, although FIG. 8 illustrates only three sets of components, the present invention is not limited to the described number of sets of components. It follows that the present invention may include one to as many sets of the components required to fill orders as they may be received. In one alternative embodiment, a bottle storage table is not used. In another alternative embodiment, more than one AOC and/or bottle storage table may be used. In other alternative embodiments of the invention, manual intervention and/or manual processes may be substituted for one or more components.
FIG. 9A illustrates a top view of an example of the bottle storage table 805 and its assembly that includes a bottle conveyor belt 901 , an array of bottle storage locations 903 , a standard gantry crane 905 , a reject conveyor belt 907 and a bottle conveyor belt 909 to feed bottles from the bottle storage table 805 to the order consolidation station. In this example, the bottle storage table 805 receives bottles filled by an automated/manual process as described above in connection with FIG. 2 . The labels on the bottles can be scanned to identify its order number. The order number can be barcodes that the host computer 201 , or in combination with a local computer, can match to a specific order number. If no match can be made or if any other inconsistencies are detected, the bottle is rejected and sent to a quality assurance station via the bottle reject conveyor belt 907 .
Once bottles arrive at the bottle storage table 805 , the standard gantry crane 905 picks up the bottles and places them into one of an array of bottle storage locations 903 . The gantry crane 905 is known in the art. Examples of such devices include 5126-620 Load to Storage H-BOT, ATS Standard Products, 305290-1370-1350-BV, H-BOT, and 5126-640 Unload from storage H-BOT, ATS Standard Products, 305290-1370-1350-BV, H-BOT, for example, as described in Canadian Patent Application No. 2,226,379, incorporated herein by reference. The local computer can determine which location to put each bottle and instruct the crane 905 . The location information is then matched and stored into the local computer along with a corresponding order number. In some embodiments, each location may hold only one bottle. In other embodiments, each location may hold more than one bottle (e.g., four) belonging to the same order. Whether the locations can hold one bottle only or more than one bottle, the local computer is configured to store their corresponding order numbers. Accordingly, when the local computer is instructed to release all the bottles belonging to one order, they can all be located.
When one or more locations are identified as having bottles to be released, the bottles in those locations can be then picked up by the crane 905 . FIGS. B-C show different perspective view of the bottle storage table.
In some embodiments, each storage location is in the form of a tube structure 1001 with a pin switch 1003 near its bottom opening (as shown in FIG. 10 ). In these embodiments, the tube 1001 structure is configured to receive the bottles via its top opening and hold them therein supported by the pin switch 1003 . When the bottles in the tube structure are to be sent over to the order consolidation station 811 , the pin 1003 is opened by another gantry crane (part of which is shown in FIGS. 9B-C ). When the pin 1003 is opened, the bottles stored in the tube structure 1001 (belong to the same order) slide down through the bottom opening of the tube structure 1001 . The bottles are then collected and sent over to the order consolidation station 811 via the bottle conveyor 909 .
In the example shown in FIG. 9A , the bottle storage table 805 has a two-dimensional array of storage locations. It should be noted that the bottle storage table 805 can have a one-dimensional array of locations or any other shape of array of locations as long as each location can be identified by the local computer.
Now referring to FIG. 11 , there is shown a more detailed example of the storage device for packages 203 . In this example, the storage device for packages 203 includes a number of shelves 807 to store various packages to be dispensed, a picking robot maintenance area 1101 , a picking robot track and the picking robot 809 , such as the MDS picker MODEL—MDS01 manufactured by KNAPP Logistics & Automation, 659 Henderson Drive, Suite I, Catersville, Ga. 30120 U.S.A. and/or Knapp Logistik Automation Ges. m. b. H., Günter-Knapp Str. 5-7 A-8075 Hart bei Graz, Osterrich/Austria. In this example embodiment, the shelves are divided into an array of identifiable locations. Each shelving location has a replenishing side 1103 and picking side 1105 . One type of package is fed into each shelving location from its replenishing side 1103 and picked up by the picking robot 809 from the picking side 1105 . The shelves are optionally arranged so that the replenishing side 1103 is vertically higher than the picking side 1105 . This allows the packages to slide 211 down to the picking side 1105 from the replenishing side 1103 .
The locations are stored in a local computer of the storage device for packages 203 . The shelf locations can be in a two-dimensional array. In such an embodiment, the picking robot grabbing mechanism 1109 is mounted on an elevator to move up/down/forward/backward. It should be noted that the shelves 807 can also be in one-dimensional array or any other shaped arrays as long as its local computer can identify each individual shelf location. Furthermore, the shelves 807 can be located on two sides of the picking robot 809 . Accordingly, the picking robot 809 is configured to pick up packages from both sides thereof. It should also be noted that three-sided, oval shaped, semi-circular shaped shelf formations and/or corresponding picking robots are also contemplated within embodiments of the present invention.
When in operation, the local computer receives instructions from the host computer 201 that include information relating to the quantity and type of drugs to be dispensed from the storage device for packages 203 . The local computer then commands the picking robot 809 to traverse on the track 1107 to the location where the package for one type of drug requested is located. The picking robot 809 then picks up the requested quantity of the packages (using its grabbing mechanism or end effector 1109 , for example, a pair of fingers) and so on until the request is filled. The request can be filled in a certain sequence parallel, and/or in a random fashion. The picking robot 809 can also have sufficient space to temporarily store all the requested packages to fill the request. In some embodiments, the picking robot 809 is configured to have only limited space to temporarily store the packages. In such embodiments, the local computer is configured to calculate the maximum number of packages (based on information of the foot print sizes of each packages) that can be fit on the limited space. The local computer then commands the picking robot 809 to pick up only the maximum number of packages per load. In an alternative embodiment, the picking robot can be replaced with an A-frame or other picking methods, including manual methods. Alternative control structures or architectures may be used with respect to the local and host computers. For example, in an alternative embodiment, the host computer or other central computer may perform one or more of the functions of the local computer.
Once the packages are picked up, the picking robot 809 traverses to the package disposing location to unload the picked packages. The picking robot 809 can be placed into the picking robot maintenance area 1101 for regularly scheduled maintenance.
FIGS. 12 and 13 show certain components of the example embodiment shown in FIGS. 9-11 and operations thereof. More specifically, FIG. 12 illustrates the bottle storage table 805 for the bottles, the picking robot 809 and the conveyor belt 803 for the literature packs. The bottles, packages and literature packs are combined in the order consolidation station 811 and put into one or more bags at the bagger 813 . In operation, bottles filled with counted pills are stored into the bottle storage table 805 (step 1301 ). When a complete set of bottles is received by the bottle storage table 805 , its local computer notifies the host computer 201 that all the bottles for a particular order have been received (step 1303 ). In response, the host computer 201 causes literature packs for the order to be printed (step 1305 ) and sent to the dispatch unit (either in a batch or individually) (step 1307 ). When the literature packs are received, they are organized such that literature packs for one order are next to each other. The dispatch unit 801 also determines the sequence of orders that the literature packs are received by reading identification codes affixed (or printed) on the literature packs. The dispatch unit 801 then sends the literature packs, as they are received and sequenced, to the order consolidation station 811 via the conveyor belt 803 . The dispatch unit 801 also notifies the host computer 201 the sequence of literature packs.
Upon receiving the information from the dispatch unit 801 , the host computer 201 then instructs the bottle storage table 805 to release corresponding bottles and the picking robot 809 to pick corresponding packages of the order (steps to 1309 and 1311 ). The example embodiment is further configured such that the bottles, packages and literature packs all arrive at the bagger 803 simultaneously for each order, although the bagger 803 can optionally receive them at different times in storage locations for later bagging. This configuration allows the bagger 803 to put the bottles, packages, and literature packs into one or more bags automatically.
Now referring to FIG. 14 , there is shown mechanical/schematic illustration of an example embodiment of the dispenser for the packages 205 and consolidation station 215 . In particular, FIG. 14 shows an example package scanning and labeling station 1401 . The station 1401 includes an induct belt 1403 configured to receive packages picked and unloaded by the picking robot 809 . The received packages are then transported to a separation and accumulation belt 1405 configured to put gaps between the packages. The separation and accumulation belt 1405 then moves the packages into a set of barcode scanners 1407 configured to detect and read barcodes from any of five exposed sides of the packages. (Since the packages are boxes, when the packages are placed on the belt 1405 , five sides are exposed other than the side that touches the belt.) In such embodiments, when the packages are replenished into the shelves, their barcodes should not be on the bottom. In some other embodiments, only a top side can be scanned as long as the packages are placed into the shelves so that their barcodes are on the top. Accordingly, any combination of barcode readers can be used as long as barcodes on the packages can be detected and read. It should be noted that in some embodiments of the present invention, the belt 1405 can be transparent so that barcodes from the bottom side of the packages can also be detected and read by a barcode reader located below the belt 1405 .
When barcodes are read, they are verified by a local computer. The local computer ensures that the scanned package actually belongs to the order that is about to be filled by the consolidation station 215 . After the barcode scanners 1407 are used, the images of the packages are captured by a camera 1409 . The images are then sent to the local computer to determine the shape and orientation of the packages as they lay on the belt 1405 . Based on the determined shape, height and orientation, the local computer commands a robot arm to pick up the package from the belt 1405 . An example of conventional computer vision software includes Adept AIM System, Motionware, Robot & Vision, Version 3.3B-Jun. 9, 1999, U.S. Pat. No. 4,835,730.
FIGS. 15A , 16 and 17 schematically show example components of the storage device for packages 203 , dispenser for the packages 205 and consolidation station 215 . FIGS. 15B-E show mechanical drawings of parts of these example components in different perspective views. As part of the dispenser for the packages 205 , the example embodiment includes the induct conveyor belt 1403 for the packages, the conveyor belt 1405 for the packages, the barcode tunnel 1407 , a order labeler 1501 , a label barcode reader 1503 and a robot 1505 . An example of conventional label printers includes Zebra Technologies Corp., Model: 90XiIII, Address: 333 Corporate Woods Parkway, Vernon Hills, Ill 60061. And, and example of conventional robots includes Staubi Corp., Model: RX60, Address: 201 Parkway West, P.O Box 189; Hillside Park, Duncan, S.C. 29334.
Similar to the example embodiment shown in FIG. 14 , the packages are transported through the barcode tunnel 1407 that detects and reads barcodes on the packages. The packages are then picked up by the robot 1505 (using its end effector 1601 as shown in FIG. 16 ). The local computer causes a patient label to be printed by the patient labeler 1501 for each package. The information printed on the labels and the form of the labels are discussed below in connection with FIG. 18 . While a package is picked up by the robot 1505 and being transported, its label is affixed to the package. Then the robot 1505 swings the package next to the barcode reader 1503 . The presence of a correct label is determined by the label barcode reader 1503 . In addition, the robot 1501 , label barcode reader 1503 , and their local computer can also be configured to cooperate with each other to detect the labels and reject any packages without a label or with an incorrect label. Once, the package is determined to have a correct label affixed thereto, the robot 1505 can drop the package into the bag opened in the bagger 813 as will be discussed below in connection with FIGS. 19-20 .
With respect to the bottles, they are transported via a metal detect conveyor 1509 which has a metal detector 1511 rejected thereon. In such example embodiments, the bottles are passed through the metal detector 1511 which determines any presence of metallic substances in the bottles. Bottles with metallic substances are rejected. The bottles belonging to one order are then placed into a bottle magazine 1513 by a pick-and-place device 1507 . An example of pick-and-place devices includes Stelron, Model: SVIP-A-M-P-6.00, X-2.00 Y-spec, U.S. Pat. No. 3,703,834, Mahwah, N.J. In this example embodiment, a bottle barcode reader is provided to ensure that correct bottles have been delivered to the bottle magazine. Once all the bottles have been loaded to the bottle magazine, they can be released into the bag opened by the bagger 813 all will be discussed below in connection with FIGS. 19-20 .
With respect to the literature packs, they are transported to the bagger 813 via the literature conveyor 803 . As the packs arrive at the bagger 813 , their barcodes are detected and checked by a literature barcode reader 1517 . The literature barcode reader 1517 and it local computer ensures that correct literature packs are to be included in the bag. As the literature packs arrive, they are discharged into the bag as will be discussed below in connection with FIGS. 19-20 .
FIG. 18 illustrates an example label 1801 to be affixed on a package. The label has patient information printed thereon. For instance, the patient information may include one or any combination of the following information: the name of the doctor; how often the package is to be taken by the patient; the name of the drug; the manufacturer of the drug; the number or strength of the drug; any warnings; any refills; and/or the number of or quantity of the packages being dispensed, directly or indirectly, to the patient, if it is standard patient label information. Other information as required may alternatively be printed or placed on the label as well.
The label, after being printed, is folded up so that one surface has adhesive placed thereon and the other surface has an identification mark (e.g., barcodes) printed thereon. An example of a folded label is shown as 1803 . The side with the adhesive is placed on its corresponding package and pressed thereon in order to securely attach the label to its package. When the label is folded up, its size is approximately, a one and one-half inch long by one and one-half inch wide. When the label is not folded, the label is about eleven inches long in its width is one and one-half inches. A wrapping tool is provided to fold up the labels.
In contrast to the prior art Outserts which do not contain information specific to any patient, the present invention advantageously includes patient specific information on the label.
FIG. 19 illustrates the steps taken by the various components, their local computers, and the host computer 201 in the order consolidation station 215 . In particular, bottles belonging to one order number are received from the bottle storage table 805 (step 1901 ). The received bottles are run through the metal detector 1511 (step 1903 ). The bottles are then mounted on the bottle magazine 1513 by the pick-and-place device 1507 (step 1905 ). Simultaneously, packages belonging to the same order number are received from the storage device for packages 203 (step 1907 ). A label is affixed to each of the received packages (step 1909 ). Again simultaneously, the conveyor belt 803 moves literature packs belonging to the same order number to the bagger. When all the items arrive, they are disposed into one or more bags at the bagger 813 .
If any error is detected, the items belonging to the same order number are all sent to a quality assurance station. If the error cannot be resolved, the order is cancelled and re-ordered. The host computer 201 reinitiates the process from the beginning to fill the order again. The example errors can be a rejected bottle because a metallic substance was detected, a patient label not being affixed to a package, incorrect literature packs being delivered, etc.
Now referring to FIG. 20 , there is shown an example embodiment of the bagger 813 in detail. The example bagger 813 includes a supply of bags 2001 , a printer 2003 , tamp 2004 , a scanner 2005 , a mechanism 2006 to open a bag and hold it open and a mechanism 2007 to seal the bag. In operation, bags are fed from the bag supply 2001 one at a time. As the bags move up through the bagger 815 , a label or information about the order that is about to be filled is placed on the bag. For example, The label may be printed and then pressed against the bag by the tamp 2004 . The label or information is then detected and read by the scanner 2005 . The scanner determines whether the correct label is printed and/or the label is properly affixed to the bag. The bag is then opened to receive the items in the manner as described above in connection with FIG. 19 . If the bag contains all the items necessary to fill the order, then the bag is sealed. Optionally, the bag is not sealed, if an error is detected. If one or more manually picked packages are required as described above in connection with FIG. 7 , then the bag is left unsealed. Although the present invention includes a bagger as described above, any container that can receive various pharmaceutical products and literature packs are also contemplated within this invention.
Now referring back to FIG. 15A , since the sealed bags are ready to be distributed or mailed, they are put on, for example, a conveyor belt 1519 . For the unsealed bags, they are put on a tote conveyor 1521 in a tote. The tote is then transferred to an operator who can then completely fill the order by manually adding the required package(s).
In order to fill order in the manner described above in connection with FIG. 19 in a continuous basis, flow logic, error detection and/or correction may be required. FIG. 21 illustrates an example process called consolidation logic 2101 and its interface with other example control logic processes for various components. The logic processes can run on the host computer 201 and/or in combination with the local computers.
For example, a literature handling process 2103 can interact with the consolidation logic process 2101 to ensure correct literature packs are included when a order is filled. As shown in FIG. 17 , the conveyor belt has three positions. Position 1 designates the position on the belt 803 in which its literature pack is ready to be disposed into the bag at the bagger 813 . Position 2 designates the position on the belt 803 in which its literature pack can be discarded if some error is detected. Position 3 designates the position on the belt in which the barcode reader 1517 shown in FIG. 15A detects and reads the barcode of the literature pack. The literature handling logic 2103 can report on the status of the literature packs in the three positions. In turn, the consolidation logic process 2101 can instruct the literature handling logic process 2103 to perform one or more tasks (e.g., accept or reject certain literature packs and/or advance the conveyor belt 803 ).
For example, in FIG. 22 , the consolidation logic 2101 starts by querying whether the literature packs are in a steady state (step 2201 ). In other words, the process 2101 is attempting to determine if the literature packs are being supplied by the conveyor belt 803 . It is also attempting to determine if any literature packs have been consolidated. It then determines if there are literature packs in positions 1 and 2 (steps 2201 and 2203 ). If the answer is affirmative, then it further determines if the literature pack in the position 2 is in the same order as the literature packs were picked by the dispatch unit 801 and fed to the conveyor belt 803 (step 2209 ). If not, the literature pack in the position 2 is discarded (step 2209 ). If affirmative, then the consolidation logic 2101 further determines if the literature pack in the position 2 is consolidated (step 2211 ). If affirmative, then the literature pack in position 2 is discarded (step 2209 ). Subsequently, the belt 803 is moved one position to repeat the processes. In this way, multiple literature packs can be put into one bag.
In some occasions, a bag at the bagger 813 cannot receive all the items. A second bag may be required to put literature packs only. This is called a literature pack only order. For such an order, the bagger 813 is not required to print a mailing label. As shown in FIG. 23 , the logic process 2101 first determines if the literatures pack in the position 2 is for literature only order (step 2301 ). If so, the literature pack is discharged (step 2303 ). If not, the process confirms the barcode is detected and read the barcode on the literature pack (step 2305 ). If so, the process further determines if the literature pack in the position 1 is for the bottles in the bottle magazine (step 2307 ). If so, the process also determines if the print queue in the bagger is in a literature only mode (i.e., not required to print any label) (step 2309 ). If so, then the literature pack is discharged (step 2303 ). FIGS. 24-26 show various other decisions to be made by the literature handling logic process 2103 and consolidation logic process 2101 .
Now referring back to FIG. 21 , besides the literature handling logic 2103 , the consolidation logic process 2101 also interacts with other processes (e.g., a robot process 2105 , patient label printer process 2107 , bagger process 2109 , etc.). It should be noted that FIGS. 21-26 are provided herein only as a part of an example embodiment in which orders are continuously filled in a high speed. Furthermore, these logic processes are specifically engineered only in the case with specific implementations. For example, if there are four or more positions for the literature packs rather than three as described above, then the logic processes would be required to be correspondingly changed. Hence, one of ordinary skill in the art can appreciate possible permutations and combination of logic processes for various control flow logic implementations.
In addition, instead of relying solely on logic processes, in other example embodiments, manual processes can also be implemented. For instance, if an error is detected, the bag and its contents can be sent to quality assurance stations where one or more operators can check and correct the errors.
FIG. 27 is a computer networking diagram illustrating an example embodiment in which the host computer 201 , local computers and their various processes are connected to each other. In this example embodiment, the host computer 201 includes two main processes: an ADS-PAC process 2701 and a CADS-PAC process 2703 . The ADS-PAC process 2701 controls the way in which pills are dispensed into bottles in an automated pill dispensing device (e.g., the ADDS shown in FIG. 1 ). A bottle table 1 (one of many tables) includes a PLC 2705 . The PLC 2705 is in turn connected to a bottle table communication node 2707 via a dedicated link 2709 (e.g., Ethernet). The node 2707 is then connected to the ADS-PAC 2701 via another dedicated link. Alternatively, the ADS-PAC and the CADS-PAC process may be combined or separated using a variety of standard methods or programming techniques.
Once bottles are filled for one or more orders, the information relating to those orders is transferred over to the CAD-PAC process 2703 . This process then carries out the consolidation process. For example, the CAD-PAC process 2703 is connected to an AOC cell communication node 2709 via a dedicated line. The controller for the patient label printer 2711 is controlled directly by the AOC node 2709 over an RS-232 line 2713 because relatively large data need to be transferred to the printer to print the patient labels (similarly, the controller for the bagger printer 2715 also has a direct connection to the AOC node 2709 ). Other devices, for example, the controller for literature dispatch unit 2717 , are indirectly connected to the AOC node 2709 via an AOC cell PLC 2719 .
FIG. 28 is an illustration of the architecture of the combined Internet, POTS (plain, old, telephone service), and ADSL (asymmetric, digital, subscriber line) for use in accordance with the principles of the present invention. In other words, instead of using dedicated lines and such communication schemes as shown in FIG. 27 , this example embodiment envisions a remotely controllable system. Furthermore, it is to be understood that the use of the Internet, ADSL, and POTS are for exemplary reasons only and that any suitable communications network may be substituted without departing from the principles of the present invention. This particular example is briefly discussed below.
In FIG. 28 , to preserve POTS and to prevent a fault in the ADSL equipment 2854 , 2856 from compromising analog voice traffic 2826 the voice part of the spectrum (the lowest 4 kHz) is separated from the rest by a passive filter, called a POTS splitter 2858 , 2860 . The rest of the available bandwidth—from about 10 kHz to 1 MHz—carries data at rates up to 6 bits per second for every hertz of bandwidth from data equipment 2862 , 2864 , and 2894 . The ADSL equipment 2856 then has access to a number of destinations including significantly the Internet 2820 or other data communications networks, and other destinations 2870 , 2872 .
To exploit the higher frequencies, ADSL makes use of advanced modulation techniques, of which the best known is the discrete multitone (DMT) technology. As its name implies, ADSL transmits data asymmetrically—at different rates upstream toward the central office 2852 and downstream toward the subscriber 2850 .
Cable television services are providing analogous Internet service to PC users over their TV cable systems by means of special cable modems. Such modems are capable of transmitting up to 30 Mb/s over hybrid fiber/coax system, which use fiber to bring signals to a neighborhood and coax to distribute it to individual subscribers.
Cable modems come in many forms. Most create a downstream data stream out of one of the 6-MHz TV channels that occupy spectrum above 50 MHz (and more likely 550 MHz) and carve an upstream channel out of the 5-50-MHz band, which is currently unused. Using 64-state quadrature amplitude modulation (64 QAM), a downstream channel can realistically transmit about 30 Mb/s (the oft-quoted lower speed of 10 Mb/s refers to PC rates associated with Ethernet connections). Upstream rates differ considerably from vendor to vendor, but good hybrid fiber/coax systems can deliver upstream speeds of a few megabits per second. Thus, like ADSL, cable modems transmit much more information downstream than upstream. Then Internet architecture 2820 and ADSL architecture 2854 , 2856 may also be combined with, for example, user networks 2822 , 2824 , and 2028 .
In accordance with the principles of the present invention, in one example, a main computing server (e.g., the host computer 201 ) implementing the process of the invention may be located on one or more computing nodes or terminals (e.g., on user networks 2822 , 2824 , and 2828 or system 2840 ). Then, various users (e.g., one or more of the local computers described above) may interface with the main server via, for instance, the ADSL equipment discussed above, and access the information and processes of the present invention from remotely located PCs. As illustrated in this embodiment, users may access, use or interact with the computer assisted program in computer system 2840 via various access methods. Databases 2885 , 2886 , 2887 , 2888 , and 2840 are accessible via, for example computer system 2840 and may be used in conjunction with client manager module 2891 , tracking module 2892 , for the various functions described above.
Viewed externally in FIG. 29 , a computer system (e.g., the host computer 201 or the local computers) designated by reference numeral 2940 has a computer 2942 having disk drives 2944 and 2946 . Disk drive indications 2944 and 2946 are merely symbolic of a number of disk drives which might be accommodated by the computer system. Typically, these would include a floppy disk drive 2944 , a hard disk drive (not shown externally) and a CD ROM indicated by slot 2946 . The number and type of drives vary, typically with different computer configurations. Disk drives 2944 and 2946 are in fact optional, and for space considerations, are easily omitted from the computer system used in conjunction with the production process/apparatus described herein.
The computer system also has an optional display upon which information screens may be displayed. In some situations, a keyboard 2950 and a mouse 2952 are provided as input devices through which a user's actions may be inputted, thus allowing input to interface with the central processing unit 2942 . Then again, for enhanced portability, the keyboard 2950 is either a limited function keyboard or omitted in its entirety. In addition, mouse 2952 optionally is a touch pad control device, or a track ball device, or even omitted in its entirety as well, and similarly may be used to input a user's selections. In addition, the computer system also optionally includes at least one infrared transmitter and/or infrared received for either transmitting and/or receiving infrared signals, as described below.
FIG. 30 illustrates a block diagram of one example of the internal hardware 3040 configured to perform various example steps as described above. A bus 3056 serves as the main information highway interconnecting various components therein. CPU 3058 is the central processing unit of the internal hardware 3040 , performing calculations and logic operations required to execute the control/operation processes of the present invention as well as other programs. Read only memory (ROM) 3060 and random access memory (RAM) 3062 constitute the main memory of the internal hardware 2140 . Disk controller 3064 interfaces one or more disk drives to the system bus 3056 . These disk drives are, for example, floppy disk drives 3070 , or CD ROM or DVD (digital video disks) drives 3066 , or internal or external hard drives 3068 . These various disk drives and disk controllers are optional devices.
A display interface 3072 interfaces display 3048 and permits information from the bus 3056 to be displayed on display 3048 . Communications with external devices such as the other components (e.g., a PLC) of the system described above, occur utilizing, for example, communication port 3074 . Optical fibers and/or electrical cables and/or conductors and/or optical communication (e.g., infrared, and the like) and/or wireless communication (e.g., radio frequency (RF), and the like) can be used as the transport medium between the external devices and communication port 3074 . Peripheral interface 3054 interfaces the keyboard 3050 and mouse 3052 , permitting input data to be transmitted to bus 3056 . In addition to these components, the internal hardware 3040 also optionally include an infrared transmitter and/or infrared receiver. Infrared transmitters are optionally utilized when the computer system is used in conjunction with one or more of the processing components/stations/modules that transmits/receives data via infrared signal transmission. Instead of utilizing an infrared transmitter or infrared receiver, the computer system may also optionally use a low power radio transmitter 3080 and/or a low power radio receiver 3082 . The low power radio transmitter transmits the signal for reception by components of the production process, and receives signals from the components via the low power radio receiver. The low power radio transmitter and/or receiver are standard devices in industry.
Although the server in FIG. 31 is illustrated having a single processor, a single hard disk drive and a single local memory, the analyzer is optionally suitably equipped with any multitude or combination of processors or storage devices. For example, the computer may be replaced by, or combined with, any suitable processing system operative in accordance with the principles of embodiments of the present invention, including sophisticated calculators, and hand-held, laptop/notebook, mini, mainframe and super computers, as well as processing system network combinations of the same.
FIG. 31 is an illustration of an example computer readable memory medium 3184 utilizable for storing computer readable code or instructions. As one example, medium 3184 may be used with disk drives illustrated in FIG. 30 . Typically, memory media such as floppy disks, or a CD ROM, or a digital video disk will contain, for example, a multi-byte locale for a single byte language and the program information for controlling the modeler to enable the computer to perform the functions described herein. Alternatively, ROM 3060 and/or RAM 3062 illustrated in FIG. 30 can also be used to store the program information that is used to instruct the central processing unit 3058 to perform the operations associated with various automated processes of the present invention. Other examples of suitable computer readable media for storing information include magnetic, electronic, or optical (including holographic) storage, some combination thereof, etc.
In general, it should be emphasized that the various components of embodiments of the present invention can be implemented in hardware, software or a combination thereof. In such embodiments, the various components and steps would be implemented in hardware and/or software to perform the functions of embodiments of the present invention. Any presently available or future developed computer software language and/or hardware components can be employed in such embodiments of the present invention. For example, at least some of the functionality mentioned above could be implemented using Visual Basic, C, C++, or any assembly language appropriate in view of the processor(s) being used. It could also be written in an interpretive environment such as Java and transported to multiple destinations to various users.
The many features and advantages of embodiments of the present invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. 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 invention. | 4y
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STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
The need to cut cables underwater is of great importance to marine engineering. With the expansion of moored systems, e.g., data buoys to underwater anchors, methods at cutting the cables attaching such systems to the anchors have become of great interest. Devices have been designed and constructed of all types for the purpose of cutting these cables.
Mechanically, most cable cutters utilize an anvil and cutter combination powered by some means to cause the cutter to sever a cable by impinging it against the anvil. Many prior systems have been entirely mechanical in operation. Later systems have introduced explosive methods of actuating the cutter against the anvil. Such actuation is initiated by mechanical means at the time the cutter is attached to the cable to be cut, or by some form of a time delay. Various forms of time delays have included trip wires, electrical detonation wires, as well as through delayed mechanical contact with the cable to be cut.
The utility of a cable cutter which is remotely actuated depends on several factors. One factor is the requirement to activate the cutter from a remote position for purposes of safety. A second factor is the desire to activate the cutter remotely at a preselected chosen time.
A particular desire for remotely controlled cable cutting is to have the ability to activate several separate cable cutters according to a preplanned sequence in a manner that firing of one cutter does not interfere with the firing of any other cutter. This capability leads to a very valuable method of planning the cutting of multiple cables through remote commands as part of a time sequence of events. Such a requirement occurs where large items tethered by several cables are to be cut such that the items released will either float to the surface in a predetermined orientation, or vice verse, are to be cut from a surface vehicle to float and settle on the bottom in a predetermined orientation.
SUMMARY OF THE INVENTION
An apparatus and method is disclosed for a remotely actuated cable cutter which is triggered by an acoustical preprogrammed and coded signal. Thus, several cables can be severed simultaneously upon a remote discrete command or separately as part of a precisely timed sequence of events.
The cutter is an improvement on presently existing art wherein the mechanical portion of the cutter is essentially a pair of hooks which guide and hold a cable on an anvil against which a cutter is driven by the detonation of an explosive cartridge. This invention has improved on the prior art by adding a self-contained electronic circuit and motor which is activated through a received acoustic coded signal from a remote emitter. Upon receiving and detecting the coded signal, the electronics control circuit activates the motor to move a lead screw shaft which pulls an initiator wire causing the release of a pin from a cocked firing plunger. When this pull pin is removed, the firing plunger under spring tension is released to actuate the firing of the explosive charge thereby causing the cutter to cut the cable.
The invention has been fitted with a pressure switch which is designed to conserve power by activating the power only when the cutter has been taken to a certain depth in the ocean. Another safety system protects the electronics and motor from premature actuation by detecting any seawater that should leak into the pressure housing. This water intrusion safety device upon detection of seawater will cause a surge current from the battery to short circuit to ground thereby blowing a fuse which disconnects the battery from use. Otherwise, a seawater short could cause the motor to turn on prematurely causing an untimely firing of the cutter.
The invention is capable of having the activating acoustic coded signal preset in a manner that is unique. Therefor, it cannot be accidentally triggered unless and until a coded signal matching the programmed coded signal is received. This capability allows several cutters to be used in an area for severing many cables either simultaneously through a single remote command signal or as a part of a timed sequence of events via several remote command signals.
OBJECTS OF THE INVENTION
An object of the invention is to provide an improved apparatus that cuts underwater cables upon activation by remote control.
A second object is to provide an improved underwater cable cutter which is explosively actuated by remote underwater acoustic signals.
Another object is to provide an improved underwater explosive actuated cable cutter which is detonated by remotely emitted coded acoustic signals.
A further object is to provide an improved explosively actuated underwater cable cutter which can be remotely controlled by acoustic coded signals that are preprogrammed so that several underwater cable cutters can be used without interfering with one another's operation.
A still further object is to present an improved explosively actuated underwater cable cutter remotely controlled by coded acoustic signals and a method whereby large underwater devices tethered by multiple cables can be released to either float to the surface or sink with the devices orientation controlled by the preprogrammed method of cutting the multiple cables.
These and other objects of the invention will become more readily apparent from the ensuing specification when taken together with the drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of the cable cutter.
FIG. 2 is a cross-section view of the cable cutter which shows the electronics.
FIG. 3 is an electronics function block diagram which displays the basic electronic functions for receiving the coded trigger signals and controlling the motor operation.
FIG. 4 is a diagram of the water intrusion fail safe circuit.
FIG. 5 is a diagram displaying the DC motor drive circuit.
FIG. 6 is a diagram showing a cable cutter attached to the cable of a tethered buoy which displays single cable cutting.
FIG. 7 is a diagram displaying a method for programmed multiple cable cutting.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The exploded view of the cable cutter shown in FIG. 1 clearly displays the pertinent aspects of the invention. Shown is a cable cutter body 10, an attached explosive actuated cutter housing 12, a clamp hook 14, an anvil 16, and an extended guide bar 18. These items can be considered as part of prior art and are not claimed as particular improvements covered in this invention.
Also shown as parts of the improvements included in this invention is an acoustic transducer 20, a pressure switch 22, a motor 24, electronics boards 26 and 28, a code select circuit 30, a battery 32, and a pressure housing 34. These items are also shown in the cross-sectional view of FIG. 2.
Referring to FIGS. 1 and 2, it is to be noted that the cable cutter body 10 has connected to it the explosive actuated cutter housing 12. The cable cutter body is carried by an installation/removal assembly 62 during the process of attaching the cable cutter to a cable to be cut. The cable to be cut is guided to the anvil 16 by the extended guide bar 18 at which time clamp hook 14 grasps the cable through the action of a spring 54 and a clamp arm 52. Once the cable is firmly grasped, installation/removal assembly 62 releases cable cutter body 10. Following this the attaching mechanism, whether it be an undersea submersible vehicle, a marine mammal, or a human diver, may retreat to a safe position for actuation of a remote triggering signal.
The explosive actuated firing mechanism is contained within housing 12 and through access of a breechblock 48 the explosive cartridge may be inserted or removed. A firing plunger 50 is shown as part of the actuator assembly.
This firing plunger is pierced by a hole containing a pull-pin 46 when in a cocked position prior, or awaiting, firing of the cutter mechanism. When pull-pin 46 is pulled from the hole of firing plunger 50, the firing plunger is spring released to cause the explosive cartridge to fire and propel a chisel towards anvil 16 thereby cutting any cable held thereon.
Pull-pin 46 is shown connected to an initiator wire 44. The initiator wire is rolled around a guide pin so that its attachment to pull-pin 46 is in a manner that the axis of the pull-pin and the wire are colinear. Initiator wire 44 is connected at its other end to a lead screw shaft 42. Lead screw shaft 42 is fitted with a gear arrangement 40 in contact with gearing on the drive shaft of motor 24.
The motor when actuated, causes the lead screw shaft to be moved along its axis putting tension on the initiator wire. This tension causes pull-in 46 to be pulled from the hole in firing plunger 50 which causes actuation of the explosive cartridge in the cutter.
During preliminary setup of the cable cutter the motor may be adjusted by operating it in reverse such that slack is provided to initiator wire 44. This allows the insertion of pull-in 46 into the hole in firing plunger 50 thereby arming the device.
Control of the motors action and operation is accomplished by an electronic control circuit contained on electronics boards 26 and 28. In addition, code select circuit 30 is part of the electronic circuit for the purpose of allowing the operator the capability of preselecting a specific signal code which when received will activate operation of the cable cutter. An electronics cover 36 shields the electronics units and battery 32 provides power to the units.
In this particular embodiment pressure switch 22 has been incorporated to keep the battery disconnected from providing power unless a certain pressure is attained which activates the pressure switch to close the battery circuit to the electronics. The pressure switch is controlled by the pressure from the surrounding hydrostatic environment received through a pressure switch pressure path 58. When the cable cutter has been taken to the proper depth and the pressure is correct, pressure switch 22 activates and closes circuits so that the battery will provide power to the electronics.
The above components, the electronics assemblies, the battery, the motor, and the pressure switch, must be kept dry from the surrounding seawater. A pressure housing 34 encapsules these components and is sealed through an O-ring seal 60 to provide a pressurized and hydrostatically secure compartment. As a fail-safe measure, should seawater accidentally invade the compartment housed by the pressure housing, the seawater could cause a short of the electronics which would result in premature operation of the motor. Premature firing of the cable cutter would then follow. To protect against such an event, a water instrusion fail-safe circuit 38 has been installed. This circuit, which will be described in more detail later, causes a short circuit of the battery if seawater is detected within pressure housing 34.
Also shown is acoustic transducer 20 which may be a hydrophone connected to the electronic circuits. The acoustic transducer will pick up a remotely transmitted coded pulse signal designed to cause activation of the cable cutter through the electronics circuitry.
FIG. 3 shows the electronic circuitry in a functional block diagram. The acoustic transducer 20 feeds its received signal to an acoustic receiver 78 which basically amplifies and bandpass filters this signal. The signal is then fed to a detection circuit 64.
The detection circuit is displayed in FIG. 3 but is not part of the claimed improvements in this invention. However for reference purposes the functional components of detection circuit 64 are set forth here. They include taking the output signal from the acoustic receiver into a frequency comparison unit 66 which also receives a reference frequency generated by reference frequency synthesizer 68. The reference frequency synthesizer receives its directions concerning what frequency to synthesize from a code select circuit 70. This code select circuit has been shown physically as item 30 in FIGS. 1 and 2. If an initial frequency received through the acoustic transducer matches the reference frequency synthesized a signal pulse is emitted by frequency comparison circuit 66 which is transmitted to a detect latch circuit 72 and a timing comparison circuit 74.
At some predetermined time after receipt of this signal pulse timing comparison circuit 74 emits a switch signal to reference frequency synthesizer 68. The reference frequency synthesizer then synthesizes a second frequency according to directions from code select circuit 70 and transmits this second reference frequency to frequency comparison circuit 66.
The time of the coded frequency signals is measured and compared via timing comparison circuit 74. Upon the first signal pulse emitted by frequency comparison circuit 66 the detect latch circuit has set and emits a signal to timing comparison circuit 74.
If a properly coded second frequency signal comes in and is positively identified with the second reference frequency a second pulse signal is emitted by frequency comparison circuit 66 which also proceeds to the timing comparison circuit. If the time interval between the first detected frequency and the second detected frequency is correct then a signal pulse is emitted from the timing comparison circuit to a motor drive circuit 80. If the timing was not correct between the two received frequencies or if there was no second frequency to be detected within the code a reset signal is emitted from timing comparison circuit 74 to return detect latch circuit 72 to its original standby condition awaiting a first coded frequency for detection again.
A clock timer 76 provides timing control to reference frequency synthesizer 68 and to timing comparison circuit 74.
The motor drive circuit 80 once activated, then causes power to be transmitted to the motor which thereafter pulls the pull-pin and fires the cable cutter mechanism.
FIG. 4 shows a circuit diagram for the water intrusion fail-safe circuit. This circuit interrupts any possible flow of current from a battery 82 to eventually power motor 30 prematurely if seawater leakage occurs within the electronics package. It is to be noted that battery 82 shown in FIG. 4 is equivalent to the physical depiction of the battery in FIGS. 1 and 2 as noted by item 32 in those FIGS. The circuit contains a fuse 84 attached to the output positive terminal of the battery. This fuse is in the circuit line which eventually travels to the motor and, once blown, blocks any possible power arriving at the motor.
Attached at the end opposite to battery connected end of the fuse is the anode terminal of a silicon controlled rectifier 86. The gate terminal of the silicon controlled rectifier is connected via a resistor 94 to one sensor of a capacitative bridge sensor. A second sensor of the capacitative bridge sensor is also connected to the end of the fuse opposite the positive terminal of the battery. The cathode terminal of silicon controlled rectifier 86 is connected to ground. Between the gate terminal of the silicon controlled rectifier and R2 are a capacitor 98 and a resistor 96 connected in parallel to ground.
Operation of this circuit is activated when water intrudes and causes a resistive circuit to occur between the sensors of the capacitative bridge sensor 90. Such a seawater short is depicted as a water bridge resistance 92.
Once this condition occurs this voltage divider network will supply a sufficiently high potential at the gate terminal of the silicon controlled rectifier to allow it to conduct. As the silicon controlled rectifier goes into conduction, its anode to cathode surge current blows fuse 84 providing the desired power disconnect. Capacitor 98 prevents spurious noise spikes from accidentally turning on the silicon controlled rectifier. The sensor probes of the capacitative bridge sensor actually consists of two concentric conductive bands etched on both sides of a circular printed wiring board.
FIG. 5 shows the circuit for the motor drive operation. A second silicon controlled rectifier 104 is used to trigger operation of the motor. This silicon controlled rectifier is open circuited until a significant voltage is detected at its gate terminal to trigger it to the on condition.
Silicon controlled rectifier 104 is connected with its anode terminal to the ground side terminal of a motor 106. This motor has been displayed in FIGS. 1 and 2 physically as item 24. In this embodiment a direct current motor is being used. The other terminal of the motor is connected to receive power from the power terminal of the battery. A capacitor is shown in this embodiment connected in parallel with the motor terminals A and B. The motor may be reversed by applying a negative DC voltage probe to terminal B and a positive probe to terminal A. For this operation, a diode 114 is placed in series with the motor to protect the input of the voltage regulator while the motor is being reversed. Current can only flow through the motor because both diode 114 and silicon controlled rectifier 104 are reverse biased.
For operation of the cable cutter the motor is turned on by a motor drive pulse received from motor drive circuit 80. This drive pulse occurs only after the appropriate acoustic code has been received and detected by detection circuit 64. The drive pulse provides a sufficient potential at the gate terminal of silicon controlled rectifier to trigger it to a conduction mode which closes the power circuit of the motor thereby initiating its operation. A threshold circuit 102 is inserted to pass the motor drive pulse and to prevent noise spikes from triggering the silicon controlled rectifier.
The application of this remote controlled cable cutter is quite versatile. A multiple of techniques are available for its employment. FIG. 6 shows its employment for cutting a single cable buoyed to the bottom of an ocean area. The cable cutter 118 is shown attached to a cable 116 which is to be cut releasing a buoy 120 from an anchor 122, thereby allowing buoy 120 to float to the surface. Triggering of cable cutter 118 occurs from a remote signal source 124 shown in FIG. 6 as mounted to a surface vessel which can be placed at a safe distance away from the release point.
It is obvious that fields of multiple buoys may be released from the remote signal source by using separate cable cutters adjusted with separate coded signal programs and attached to each of the cables. By such method all cables may be preprogrammed to be cut simultaneously, or in the alternative, may be preprogrammed to be cut in a preselected sequential fashion.
FIG. 7 shows an example of multiple cable cutting techniques which could require the preprogramming of a predetermined sequential cable cutting series of events. As shown, an underwater tower 128 is supported from the surface of the ocean by buoys 126 through the use of cables 132. Cable cutters 134 have been attached to each cable 132.
Each cable cutter 134 is preprogrammed to be activated upon receipt of its own preselected coded signal. The preprogrammed sequence can be adjusted such that the cable cutters attached to the cables holding up a lower end or base 142 of tower 128 are cut first. This procedure allows the base to begin sinking while an apex or top 140 of tower 128 remains attached to buoys holding it in place. The base 142 of the tower will swing down and the tower will approach the desired vertical orientation. At the time vertical orientation is accomplished, the cable cutters attached to the cables holding top part 140 of tower 128 are activated to cut their respective cables. This then will allow the tower to settle to a position on the bottom of the ocean area in a manner that the tower will be erect.
Clearly such a programmed method of sequentially cutting cables to control orientation of vessels to be installed in the ocean may be reversed for a similar preprogrammed procedure in cutting cables of vessels which are moored to the bottom but are to be returned to the surface in a predetermined orientation. Also it is clear that the remote coded signal may be emitted from a multitude of select sources located at distances removed from the cables to be cut.
Obviously, many modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described. | 4y
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This application is a division of application Ser. No. 07/459,399, filed Dec. 29, 1989, now U.S. Pat. No. 5,120,209.
BACKGROUND OF THE INVENTION
The invention is directed to a novel mold for molding articles, particularly applying tread to tires or retreading tires, and novel methods associated therewith. However, though the invention is primarily directed to the field of manufacturing new or retread tires, it is equally applicable to molding virtually any object and particularly objects of different sizes which are molded in a single mold.
The related art is particularly characterized by many patents in the name of Kenneth T. MacMillan, typical of which is exemplified by U.S. Pat. No. 3,990,621 issued Nov. 9, 1976. The latter patent discloses a plurality of matrices movable between open and closed positions thereof with the latter position defining a generally annular chamber having a vertical axis. An example of a similar retreading apparatus is disclosed in U.S. Pat. No. 3,042,966 issued Jul. 10, 1962 to William J. Laycox which also discloses a plurality of matrices movable between open and closed positions thereof with the latter position defining a generally annular chamber having a horizontal axis. Reference can also be made to the various patents cited in U.S. Pat. No. 3,990,821, and many other patents most notably classified in U.S. Cl. 425/19 et seq.
SUMMARY OF THE INVENTION
The present invention is directed to a novel apparatus for molding articles of different lengths, including different circumferences, in a mold cavity, be it elongated or annular. In a first apparatus of the invention the mold cavity is annular and is formed by a plurality of individual pitches having transverse faces in generally face-to-face abutment in a closed position of the mold cavity. At least several of the pitches are of different circumferential lengths, and in a closed position of the mold cavity the pitches define a predetermined mold configuration which includes portions at angles to the circumference of the article or tire molded in the mold cavity. Most importantly, the mold configuration matches circumferentially across all of the transverse faces of abutting pitches irrespective of the location of the pitches relative to each other and irrespective of the number of the pitches. Accordingly, irrespective of the manner in which the pitches are located relative to each other or the number and size pitches, an annular article, such as a tire, can be molded of different circumferences/diameters in the same mold, but the same predetermined mold configuration is maintained irrespective of the particular circumference/diameter molded in the mold. Accordingly, the plurality of pitches which collectively define the mold matrix can be increased in number and/or size for larger tires and decreased in number and/or size for smaller tires.
By virtue of a mold matrix constructed from a plurality of pitches which match at each and every abutting face or pitch plane, numerous advantages are achieved, not the least of which is the fact that less costly molds are required by a new tire manufacturer or a retreader than, for example, if a mold or mold matrix could be used only to manufacture a single sized tire. This is particularly important with belted tires because oversized tires cannot be buffed smaller to fit in smaller molds because the belts would be damaged. Furthermore, smaller belted tires cannot be pressurized and stretched to fit larger molds because the new rubber will not be sufficiently pressurized to form the tread and obtain a proper bond between the new tread and the old tire. In either of the latter two cases the integrity of the tire body can be damaged because the belts can be broken or the bond between the belts and other components of the tire can be weakened.
Another major aspect of the present invention is the fact that the mold opens and closes relative to an associated tire in the absence of tire distortion because tire size and mold size are precisely mated. Thus, tires cannot be damaged during the molding thereof.
In further accordance with this invention, the circumferential lengths of the pitches are all relatively short and therefore the abutting faces between adjacent pitches create a relatively large number of opposing abutting pitch surfaces through which air and gas can vent to atmosphere during molding to minimize and eliminate the need for conventional vent holes drilled through conventional matrices. However, if additional venting is required, the pitch faces of the pitches can be scribed, which is accomplished quickly and less expensively by a sawing operation than by drilling conventional matrix vents. Furthermore, the pitches are preferably clamped in groups or segments, and the endmost pitches of each group or segment is provided with a depression or well outside the tread diameter into which the scribe lines will run so that any overflow rubber will flow along the scribe lines, enter the depressions and solidify. This excess rubber can be easily torn from the cured/molded tire eliminating the need for trimming.
Years ago tread designs with variable pitches were introduced on passenger tires to lessen road noise. However, heretofore variable pitch tread designs did not allow repetitive diameter change without unsightly interruption in tread design except by reconstruction of the mold and/or matrix. In keeping with the present invention, each pitch, irrespective of its circumferential length, matches across the pitch plane of all abutting pitch faces. With the present invention it is immaterial whether one pitch of one circumferential length is substituted for another pitch of a different circumferential length, or different pitches are added or subtracted to alter tire diameter/circumference, because in each case tread configuration matches at all abutting pitch surfaces or faces resulting in an extremely accurately dimensioned tire with an unvarying tread configuration. Such tires have no tread gaps, spaces, blemishes or the like, as might be created by inserting blank shims between a pair of adjacent mold segments, as has been done in the past. Through the utilization of a multiplicity of pitches varying in circumferential size, but all with tread matching at abutting pitch planes or faces, new tires and retread tires of different diameters/circumferences can be made economically and rapidly in but a single mold.
With the above, and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims and the several views illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a novel mold constructed in accordance with this invention, and illustrates four mold sections in the open position thereof, each slidably carried by an arm of a supporting table with adjacent mold sections being moved between open and closed positions by fluid motors.
FIG. 2 is a fragmentary top plan view of the mold of FIG. 1, and illustrates the mold sections in their closed positions.
FIG. 3 is a cross sectional view taken generally along line 3--3 of FIG. 2 and illustrates a tire centering hub carried by a centering post of the table and an annular mold chamber formed by a plurality of pitches or inserts in abutting face-to-face relationship along pitch planes thereof.
FIG. 4 is a schematic top plan view of the mold of FIGS. 1 and 2 with parts removed for clarity and illustrates a heat chamber and three mold segments associated with each of the four mold sections and six pitches carried by each mold segment.
FIG. 5 is an enlarged fragmentary cross sectional view taken along line 5--5 of FIG. 2, and illustrates details of one of the heaters, and bottom and top side plates of the mold between which are sandwiched a pair of clamps of a clamp assembly holding together the pitches.
FIG. 6 is a cross sectional view taken generally along line 6--6 of FIG. 5, and illustrates a bottom sidewall plate of one of the mold sections in transverse spanning and sliding relationship to an associated arm of the mold table.
FIG. 7 is a cross sectional view taken generally along line 7--7 of FIG. 6, and illustrates further details of a mold segment guide and its associated retaining plate.
FIG. 8 which appears on the sheet of drawing containing FIGS. 16-18, is a cross sectional view taken generally along line 8--8 of FIG. 6, and illustrates details of the bottom sidewall plate, and a cam roller and sidewall wear plate carried thereby.
FIG. 9 is a cross sectional view taken generally along line 9--9 of FIG. 7, and illustrates further details of the mold segment guide.
FIG. 10 is a top plan view of one of the heaters of FIG. 4, and illustrates the specifics of the construction thereof.
FIG. 11 is an enlarged cross sectional view taken generally along line 11--11 of FIG. 10, and illustrates a steam chamber defined by walls of the heater.
FIG. 12 is a top plan view of one of the matrix segments, and illustrates six pitches or inserts carried thereby, and a spring cap for maintaining adjacent matrix segments in biased spaced relationship.
FIG. 13 is an enlarged end view taken generally along line 13--13 of FIG. 12, and illustrates opposite clamping bars and a transverse bolt for retaining the segment and pitches in assembled relationship.
FIG. 14 is a cross sectional view taken generally along line 14--14 of FIG. 13, and illustrates one of the spring caps, its associated spring and a housing therefor.
FIG. 15 is an end view of one of the clamping bars of the matrix segment, and illustrates a bore for receiving the cylinder housing of FIG. 14.
FIG. 16 is an end view taken generally along line 16--16 of FIG. 13, and illustrates one of the six pitches or inserts of the matrix segment.
FIG. 17 is an end elevational view taken generally along line 17--17 of FIG. 13, and illustrates the exterior of the pitch or insert of FIG. 16.
FIG. 18 is a diagrammatic enlarged view of one of the four mold sections of FIG. 4, and illustrates three mold or matrix segments thereof, each including six pitches of varying circumferential distances, and two of the sets or groups of pitches being clamped together by an associated clamping assembly, and each clamp carrying a pin for limiting or preventing circumferential sliding motion of the associated matrix segment.
FIG. 19 is an elevational view taken generally along line 19--19 of FIG. 13, and illustrates six pair of pitches with six pitches located on opposite sides of a medial plane taken through the annular mold cavity with all pitches in face-to-face abutment at pitch planes thereof and with the mold configuration matching lengthwise across all of the pitch faces irrespective of the location of the pitches relative to each other and irrespective of the number of the pitches per mold segment.
FIG. 20 is a top plan view of one of the four mold sections of FIG. 1, and illustrates one of four top sidewalls and its associated retaining bar and handle.
FIG. 21 is a side elevational view taken generally along line 21--21 of FIG. 20, and illustrates details of the retaining bar and handle.
FIG. 22 is an enlarged fragmentary view taken generally along line 22--22 of FIG. 1, and illustrates a fluid motor cylinder connected to one mold section and its associated piston rod connected to an adjacent mold section.
FIG. 23 is a cross sectional view taken generally along line 23--23 of FIG. 22, and illustrates the manner in which a piston rod retainer plate is secured to a retainer ring and an associated heater of a mold section.
FIG. 24 is a cross sectional view taken generally along line 24--24 of FIG. 22, and illustrates the manner in which a cylinder retaining plate is secured to a retainer ring and an associated heater of a mold section.
FIG. 25 is an enlarged view of the encircled portion of FIG. 1, and illustrates a mechanism for aligning the tire centering hub of FIG. 3 with the annular mold cavity.
FIG. 26 is a fragmentary side elevational view taken generally along line 26--26 of FIG. 25, and illustrates a mechanism for vertically adjusting the tire centering hub relative to the centering post.
FIG. 27 is a radial sectional view through one of the mold sections, and illustrates a spacer positioned between upper and lower pitches to vary tire tread width.
FIGS. 28, 29 and 31 are top plan views of another mold constructed in accordance with this invention, and illustrates a plurality of pitches or inserts of varying lengths, and illustrates the manner in which all adjacent tread configurations match across pitch planes or abutment planes of all adjacent pitches.
FIG. 30 is a cross sectional view taken generally along line 30--30 of FIG. 29, and illustrates a pair of the adjacent pitches and an insert therebetween.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A novel apparatus, mold or machine constructed in accordance with this invention is generally designated by the reference numeral 10 (FIGS. 1-4), and includes four identical mold sections 11, 12, 13 and 14. The mold sections 11-14 are mounted for reciprocal sliding movement upon respective arms or cross arms 15, 16, 17, and 18 of a table 20 (FIG. 3) between an open position (FIGS. 1 and 4) and a closed position (FIGS. 2 and 3).
Each mold section 11-14 (FIG. 4) carries three generally identical mold or matrix segments, namely, matrix segments 21-23 carried by the mold section 12, matrix segments 24-26 carried by the mold section 13, matrix segments 27-29 carried by the mold section 14, and matrix segments 30-32 carried by the mold section 15. All matrix segments 21-23 are in generally spaced relationship from each other (FIG. 4) when the mold sections 12-15 are open and are moved circumferentially closer to each other and radially inwardly when the mold sections 12-15 are moved from the open position (FIGS. 4 and 18) to the closed position (FIGS. 2, 3 and 19).
Each of the matrix segments 21-32 carries six pairs of pitches, elements or inserts 41-46 (FIGS. 4, 12, 18 and 19) in which only the pitch pairs 41-46 associated with the matrix segment 22 of the mold section 12 have been individually numbered. However, it is to be understood that the remaining matrix segments 21 and 23-32 each includes six pairs of such pitches 41-46, as will be described more fully hereinafter. Furthermore, the pairs of pitches 41-46 of the matrix segment 22 are rigidly, though releasably, clamped together by a matrix segment clamp or clamping assembly 35, and a like, though unnumbered clamping assembly 35 is associated with the remaining matrix segments 21 and 23-32 to rigidly secure the pairs of pitches 41-46 therein. Accordingly, seventy-two pairs of pitches 41-46 or six pairs of pitches 41-46 per matrix segment 21-32 defines an annular mold or matrix cavity 40, as is best illustrated in FIG. 3 and visualized in FIGS. 1, 2 and 4. It is within the annular matrix or mold cavity 40 that a tire T (FIG. 3) is positioned with its beads B, B aligned by an associated tire aligning or centering hub 50 carried by a hub centering post 51 supported by the table 20. Thus, in the closed position of the mold 10, including the four mold sections 11-14 thereof, the tire 10 is subjected to heat and/or pressure in a conventional manner to mold the tire T, be it a new tire or a retread tire. After the molding operation the mold 10 and specifically the mold sections 11-14 are moved from the closed position (FIG. 2) to the open position (FIGS. 1 and 4) to permit the removal of the tire T therefrom.
The specifics of the mold 10 will now be described particularly with respect to the mold section 12, and this description is equally applicable to the identical mold sections 11, 13 and 14.
The mold section 12 is mounted upon the cross arm 16 of the table 20 for reciprocal sliding movement toward and away from the centering post 51, and the construction thereof will be best understood by reference to FIGS. 3, 5, 6, 7 and 9 of the drawings. The cross arm 16 is a generally inverted U-shaped steel beam 52 which is welded (not shown) to a diagonal brace 53, (FIG. 3) and to a vertical leg 54. The brace 53 and the leg 54 are also welded to each other and the leg 54 is in turn welded to a foot or pad 55 (FIG. 3). A generally square-shaped guide bar 56 of wear-resistant metal is welded to the steel beam 52. A generally inverted U-shaped outer segment guide 57 and a similarly contoured inner segment guide 58, each constructed from wear resistant metal, are in spaced relationship to each other (FIG. 3) and are each in straddled relationship to the guide bar 56. The segment guides 57, 58 are each adjustably connected to a web 61 of an inverted U-shaped guide channel or guide beam 59. Two hexhead bolts and locknuts 62 and two headless set screws and hexhead locknuts 63 secure the segment guides 57, 58 to the web 61 of the guide channel 59. Essentially the set screws and hexhead bolts pass freely through bores (not shown) in the web 61 and are threaded in threaded bores (not shown) of the segment guides 57, 58. With the locknuts loose, the hexhead bolts and headless set screws can be threaded or unthreaded as need be to adjust the planar disposition of the web 61 and all components carried thereby including, of course, the mold section 12. A bushing plate 64, (FIGS. 5 and 7) having an opening (unnumbered) therethrough is welded to the web 61 and a generally rectangular wear plate 65 is also welded or bolted to the web 61 in underlying sliding relationship to a wear plate 66 of a generally rectangular configuration (FIG. 6) bolted to an underside of a generally arcuate bottom sidewall plate 70 which is of a three-ply composite construction, as is best illustrated in FIG. 8. The bottom sidewall plate 70 (FIG. 8) is formed of an arcuate steel plate 71, an arcuate tempered hardboard plate (Masonite) 72 and an arcuate sheet of glass cloth 73 sandwiched between the steel plate 71 and the tempered hardboard plate 72. A plurality of holes 74 (FIG. 6) passed through the bottom sidewall plate and receive hexhead bolts 75 therein. Three other openings (unnumbered) arcuately spaced from each other each receive a hexhead bolt 76 which carries a cam roller 77.
The bolts 75 secure a heater, heater unit or heater assembly 80 against the dense tempered hardboard plate 72 of the bottom sidewall plate 70, as is most readily apparent from FIGS. 5 and 7 of the drawings.
The heater 80 is formed by an inside metallic ring 81 in radially spaced relationship to an outside metallic ring 82 between which are sandwiched and welded an upper metallic band 83 and the lower metallic band 84. Opposite end plates 85, 86 (FIG. 10) are welded to the plates 81-84 and collectively define therewith an arcuate steam chamber 87 having steam inlet/outlet ports 88 at opposite ends thereof for circulating steam in a conventional manner through the steam chamber 87. A plurality of grease fittings 89 are connected to the heater 80 and ports or bores 91 thereof open through an inner circumferential or arcuate surface 90 of the metallic ring 81 to lubricate the same and facilitate circumferential sliding therealong of the matrix segments 21-23, as will be more apparent hereinafter.
A circumferential sheet of insulation 92 is sandwiched between the outside ring 82 of the heater 80 and a circumferential retaining ring 95 to which is welded a pair of identical triangular gusset plates 96 in turn bridged by and welded to a base plate 97 having an opening (unnumbered) aligned with the opening (also unnumbered) of the bushing plate 64. A pivot pin 98 is slidably received in the bore (unnumbered) of the base plate 97, the bore (unnumbered) of the bushing plate 64 and a bore (also unnumbered) in the web 61 of the guide channel 59. In this fashion the entire mold section 12 can pivot about a vertical axis through the pivot pin 90 during open and closing motion of the mold sections 11-14. A pair of plates 99, 99 are welded to the bushing plate 64 and removably receive a pin 100 which prevents the entire mold section 12 from being lifted vertically from the arm 16.
After each of the four heaters or heater sections 80 have been secured by the bolts 75 in upstanding relationship to the bottomside of wall plate 70 of each of the mold sections 12-15, each of the matrix segments 21-32 is assembled by selecting pairs of pitches 41-46 and securing the same together by the clamps or clamp assemblies 35 in a manner which will be most readily apparent with respect to FIGS. 12-19 of the drawings.
Each clamp assembly 35 is formed by a pair of identical mirror image clamp bars, namely, a lower clamp bar 35L and an upper clamp bar 35U. The "L" and "U" designations are utilized simply to indicate that the clamp bar 35L is positioned most closely adjacent the bottom sidewall plate 70 at the lower side or bottom of the annular matrix cavity 40, as viewed from above in FIG. 5, whereas the clamp bar 35U is the higher or upper clamp bar relative to the matrix cavity 40.
Each of the clamp bars 35L, 35U is of a generally arcuate configuration (FIG. 12) and is set-off by an outer circumferential surface 101, an inner circumferential surface 102, outer peripheral surface 103, an inner peripheral surface 104, and opposite end faces or surfaces 105. Cylindrical bores 106 are formed in each of the clamp bars 35L, 35U and open through one of the end surfaces 105. Circumferential and radial saw cuts 107, 110 open the bore 106 through the surface 102 of each clamp bar 35L, 35U and set-off therebetween clamping legs 108, 109. Socket head cap screws 111 pass freely through openings (FIG. 15) in each of the legs 109 and are received in threaded bores in each of the legs 108 which function to clamp within each bore 106 a spring-biasing mechanism 115 for spacing adjacent matrix segments 21-32 away from each other when the mold sections 12-15 are opened, as will be described more fully hereinafter. The outer peripheral surface 103 of each clamp bar 35L, 35U includes a generally rectangular recess 112 adjacent each end face 105, and a generally elongated through-slot 113 which is located generally centrally of each recess 112. A bolt 114 (FIG. 13) passes through each of the through slots 113 and opposite threaded end portions (unnumbered) receive spacers 115 and threaded nuts 116 for clamping the pairs of pitches 41-46 between the clamp bars 35L, 35U. The inner peripheral surfaces 104 of the clamp bars 35L, 35U also have generally arcuate grooves 117 which open in opposing relationship to each other (FIGS. 5 and 13) and receive therein ribs associated with upper pitches 41L-46L and lower pitches 41U-46U, the pairs of pitches 41-46, as will be described more fully hereinafter.
Each spring-biasing mechanism 115 (FIG. 14) includes a cylindrical housing 121 which houses a compression spring 122 between a retaining slit pin 123 and an enlarged end portion 124 of a spring cap 125 having an end portion 126 projecting outwardly of an opening 127 of the housing 121. Each spring-biasing mechanism 115 is slid into an associated one of the bores 106 after which the socket head cap screws 111 (FIG. 15) are tightened to draw the legs 107, 108 closer to each other and thereby tightly grip the cylindrical housing 121. The cylindrical housing 121 can be clamped within the bore 106 in numerous positions which is dictated by desired spacing between the segments 21-32 which in turn is dictated by the particular diameter/circumference of the tire T which is molded in the mold cavity 40.
One or more radial bores 128 (FIGS. 12 and 18) are formed in the inner circumferential surface 102 and these may be threaded or plain to receive threaded or plain stop pins 129 which cooperate with the cam roller 77 (FIG. 6) of each bottom (and top) sidewall plate 70 to limit circumferential movement of the matrix segments 21-32 relative to their associated mold sections 12-15 or selectively prevent any such circumferential motion, as will be described more fully hereinafter. However, as an example thereafter, in FIGS. 4 and 18 it will be seen that the matrix segments 21, 22 and 23 are in their open position spaced from each other by the projecting end portions 126 of the spring-biasing mechanisms 115 with each outer circumferential surface 101 being in abutting circumferential sliding engagement with the lubricated circumferential surface 90 of the associated heater 80. One stop pin 129 of the matrix segment 21 contacts the left-most cam roller 77 of the mold section 12 which prevents the matrix segment 21 from moving further to the left beyond the position shown in FIGS. 4 and 18 under the influence of the spring-biasing mechanisms 115 between the matrix segments 21, 22. Likewise a stop pin 129 of the matrix segment 23 (FIG. 4) contacts the right-most cam roller 77 of the mold section 12 which prevents the matrix segment 23 from moving further to the right beyond the position illustrated in FIG. 4 under the influence of the spring-biasing mechanisms 115 between the matrix segments 22, 23. Finally, two stop pins 129 (FIGS. 4 and 18) embrace the centermost cam roller 77 of the mold section 12 and essentially prevents circumferential sliding movement of the matrix segment 22 except for extremely limited distances, both to the left and to the right in FIG. 18, in this case under the influence of the spring-biasing mechanisms 115 between the matrix segments 21, 22 and the matrix segments 22, 23. Thus, the matrix segments 21-23 are automatically circumferentially moved away from each other under the influence of the springs 122 (FIG. 14) of the spring-biasing mechanisms 115 when the mold sections 12-15 move from the closed to the open positions thereof.
The pair of pitches 46 will be described with particular reference to FIGS. 13, 16, 17 and 19, and the description thereof is applicable to the pairs of essentially identical pitches 41-45 except for specific circumferential or lengthwise dimensions which differ in a manner to be described more fully hereinafter.
The upper pitch 46U and the lower pitch 46L of the pair of pitches 46 each includes respective outer circumferential surfaces 131U, 131L; each traversed by an outwardly opening U-shaped slot or channel 129U, 129L; respective inner circumferential surfaces 132U, 132L; respective outer annular surfaces 133U, 133L; respective inner annular surfaces 134U, 134L; respective medial circumferential abutting surfaces 135U, 135L; and radial plane or pitch plane abutting surfaces 136U, 137U; 136L, 137L. The outer annular surfaces 133U, 133L each includes an arcuate rib 148 which accurately locates in the arcuate groove 117 of the associated clamping bar 35U, 35L (FIG. 13). The medial circumferential abutting surface 135U of the pitch 46U has an arcuate rib 141 which is received in an arcuate groove 142 of the pitch 46L (FIG. 13). The interengaged ribs 148, 141 with the associated grooves 117, 142 assures that the pitches 46U, 46L, as well as the remaining pair of identically constructed pitches 41-45, are accurately maintained in precise relationship when releasably secured together by the clamping bar assembly 35 associated therewith.
The inner circumferential surface 132U, 132L of all of the pairs of pitches 41-46 carried by all of the matrix segments 21-32 collectively define the annular mold or matrix cavity 40 (FIG. 19) and the particular tread configuration or pattern 60 thereof. In FIGS. 13, 16 and 19, the inner circumferential surface 132U is defined by an outermost land 143, an adjacent upstanding zig-zag shaped mold rib 144 having an upper face in which are located four upwardly opening generally rectangular recesses 145, a medial land 146, an inner most zig-zag upstanding mold rib 147 having generally rectangular upwardly opening recesses 148 and an innermost land 149. When the tire T is molded, either as a new tire or a retread tire in the mold cavity 40, the lands 143, 146, 149 of all of the pairs of pitches 41-46 of all of the matrix segments 21-32 define the treads or lugs of the tire T whereas the tire grooves are formed by the mold ribs 144, 147.
An extremely important aspect of the present invention is the manner in which all circumferentially adjacent lands 143, 146, 147 and all circumferentially adjacent ribs 144, 147 match across a radial plane or pitch plane (generally P--P of FIG. 19) passing through and/or defined by the abutting radial or pitch abutting surfaces 136U, 136L of one of the pairs of pitches 41-46 which abuts the pitch surfaces 137U, 137L of any of the other pairs of pitches 41-46. In the example of the invention illustrated in FIG. 19, there are five pitch planes P--P, and for ready reference, the pitch planes between the pairs of pitches 41, 42 are designated as the pitch plane P41,42--P41,42; the pitch plane between the pairs of pitches 42, 43 by the pitch plane designation P42,43--P42,43, etc. Since the pitch plane abutting surfaces 136U, 136L; 137U, 137L are not parallel (see FIGS. 12, 16, 17 and 18), the various pitch planes P41,42-P41,42 through P45,46--P45,46 are not parallel to each other but they generally merge at an axis A (FIGS. 4 and 18) of the matrix cavity 40 when the mold sections 12-15 are closed. Three parallel circumferential planes (FIG. 19) which are normal to the axis A of the matrix cavity 40 are designated as the planes Pu1--Pu1; Pu2--Pu2; and Pu3--Pu3. The planes Pu1--Pu1 and Pu3--Pu3 are shown intersecting each of the pitch planes P41,42--P41,42 through P45,46--P45,46 at the matching points or lines of contact Pm1 of one side of the mold ribs 44 while the plane Pu3--Pu3 likewise passes through like matching points/lines of contact Pm2 at the lower side of the mold ribs 144, as viewed in FIG. 9. The plane Pu2--Pu2 passes generally symetrically through all of the upwardly opening rectangular recesses 145, and these planes Pu1--Pu1 through Pu3--Pu3 evidence the manner in which irrespective of the irregular or angular nature of the mold ribs 144, all pitches 41U-46U match at each of the pitch planes P41,42--P41,42 through P45,46--P45,46, and this matching across these pitch planes occurs not only when the pairs of pitches 41-46 are positioned in the exact adjacent relationship as shown in FIG. 19, but also if any of these pitches are reoriented relative to each other or exchanged for a different pitch, as will be more apparent hereinafter. Furthermore, this interchangeability is significant because each pitch 41U, 41L through 46U, 46L of each pair of pitches 41-46 is of a different circumferential length (generally L in FIG. 19) as measured normal to and between the pitch surfaces 136U, 137U of the pitches 41U-46U and 136L, 137L of the pitches 41L-46L with the specific distances being respectively designated as L41-L46. The manner in which the pairs of pitches 41-46 are selected and associated with the various matrix segments 21-32 to mold tires T of different diameters/circumferences within the mold 10 will be described subsequently herein.
After the matrix segments 21-23, 24-26, 27-29 and 31-32 have been clamped together by the clamping assemblies 35 and placed in the respective mold sections 12-15 (FIG. 4), each mold section 21-32 is closed by a top sidewall plate 150 which is of a construction generally identical to the bottom sidewall plate 70, and therefore identical, through primed, reference numerals have been applied thereto. As is best illustrated in FIG. 1, after each of the top sidewall plates 150 has been positioned above the matrix segments associated with each mold section 12-15, each top sidewall plate 150 is fastened to its associated mold section 12-15 by a retaining bar 151 (FIGS. 1, 5, 20 and 21) defined by a base plate 152 having a central notch 153 and axially opposite openings 154. A handle plate 155 having a hand grip and hoist hook engaging opening 156 is welded to the base plate 152. Bolts 157 pass through the openings 154 and are threaded into threaded bores 158, 159 (FIGS. 23 and 24, respectively) of respective piston rod retainer brackets 160 and fluid cylinder retainer brackets 170 carried one each at circumferentially opposite ends of each retaining ring 95 by being welded thereto. Each piston rod retainer bracket 160 includes a pair of side plates 161, 162 (FIGS. 22 and 23) bridged by a face plate 163 welded thereto and having a threaded bore 164. Each of the side plates 161 has one of the threaded bores 158 formed therein to receive one of the bolts 157. The threaded bore 164 threadly receives a threaded end portion (unnumbered) of a fluid motor piston rod 181 of a fluid motor cylinder 182 of a fluid motor 180 carried by each of the fluid cylinder retaining brackets 170. Each fluid cylinder retaining bracket 170 includes side plates 171, 172 and a face plate 173 secured therebetween to which is connected the fluid motor cylinder 182. The side plates 171 of each fluid cylinder retaining bracket 170 includes one of the threaded bores 159 (FIGS. 22 and 24) for receiving one of the bolts 157. Fluid in the form of liquid or gas from an appropriate source is controllably delivered to the cylinders 182 and exhausted therefrom through appropriate regulating valves to simultaneously move the mold sections 11-14 from the open (FIGS. 1 and 4) to the closed (FIGS. 2 and 3) positions and vice versa during which time the mold sections 11-14 slide along the respective cross arms 15-18.
The tire T must be accurately centered relative to the matrix cavity 40, particularly if the matrix cavity 40 is increased in width in a manner to be described more fully hereinafter. However, irrespective of such increase in matrix cavity width, means generally designated by the reference numeral 190 (FIGS. 3, 25 and 26) is associated with the hub centering post 51 and the tire centering hub 50 (FIG. 3) to achieve accurate location of the tire T within the matrix cavity 40, namely, a medial plane through the tire T is coincident to the medial plane Pm (FIGS. 5 and 19). The tire centering/aligning mechanism 190 includes a mounting channel 191 having legs 192, 193 welded to the hub centering post 51. A web 194 has a central opening (unnumbered) which matches an opening (not shown) in the center of a circular rotatable selector disk 195 having a handle 196 and a plurality of bolts 201-204 threaded into threaded bores (not shown) of a periphery of the disk 195. A spring-biased ball detent locking mechanism 205 is carried by the web 194 and its ball (unnumbered) can selectively mate with a plurality of recesses 206 of the disk 205. The heads of the bolts 201-204 project different distances away from the peripheral surface (unnumbered) of the disk 195 and, if required, can be threaded or unthreaded for further minor adjustment. An individual one of the bolts 201-204 can be positioned at the twelve o'clock position shown in FIGS. 3 and 26 which in FIG. 26 is occupied by the bolt 201. An edge 211 of a hub supporting tube 212 of the tire centering hub 50 (FIG. 3) rests upon whichever of the bolts 201-204 is at the twelve o'clock position. Thus, by rotating the disk 195 and placing any one of the bolts 201-204 in the twelve o'clock position (FIGS. 3 and 26) the edge 211 of the hub supporting tube 212 can be selectively elevated or lowered to accurately support the tire centering hub 50 in such a manner that a center plane through the tire T corresponds to the plane Pm of the matrix cavity 40, as shown in FIG. 3.
The hub supporting tube 212 is connected by a plurality of radial ribs or spiders 213 (FIG. 13) to a central cylindrical sleeve 214. A bottom rim half 215 is welded to the central sleeve 214 while an upper rim half 216 is removably and adjustably secured to the central rim portion 214. A normally closed valve 217 is connected to a line 218 which is placed in fluid communication with a suitable source of compressed air. The tire T, after being buffed and built-up, is placed over the bottom rim half 215 which forms an airtight seal with the bottom tire bead B and the top rim half 216 is then placed over the cylindrical rim portion 214 and conventionally locked thereto which automatically opens the valve 217 and pressurizes the interior of the tire T. The matrix cavity 40 is closed by the rods 181 being retracted into the cylinders 182 drawing the mold sections 12-15 circumferentially toward each other which also slides the mold sections 12-15 radially inwardly along the respective arms 15 through 18, as is readily apparent from FIGS. 1 and 2. Moreover, the circumferential closing of the mold sections 12-15 slides the matrix segments 21-32 relatively circumferentially against the bias of the springs 122 of the mechanisms 115 until all pitch surfaces 136U, 136L and/or 137U, 137L of all endmost pairs of pitches 41-47 of all segments 21-32 are brought into intimate abutting relationship to close the matrix cavity 40. After a predetermined time period the sections 21-32 are opened, the entire tire centering hub 50 and the tire T is lifted from the mold by a hoist or the like, the hub 50 is disassembled and the process is repeated.
OPERATION
It will be assumed for the purposes of the description of the operation of the mold 10 that the annular mold or matrix cavity 40 has been made to a median matrix tread diameter of 421/4" which is a circumference of approximately 132.732" requiring 33.1830" of mold cavity circumference per each mold section 11-14 which in turn is 11.061" per each matrix segment 21-32. The pitch lengths L41-L46 are respectively 2.2853", 1.4999", 2.0889", 1.5981", 1.8926", and 1.6962" or a total of 11.061". Therefore by assembling the pitches 41-46 of FIG. 19 t o form the matrix segment 22 in the manner described and identically placing identical pairs of pitches 41-46 in the remaining matrix segments 21 and 23-32, the twelve segments multiplied by 11.061" per segment equals the circumference of 132.732" and, of course, the latter divided by π equal a tread diameter of 42.2499 or 421/4" diameter.
While the pitches 41-46 of all matrix segments 21-32 have been described in the last example as being arranged in the numerically consecutive order of 41-46, as shown in FIG. 19, these pitches can be arranged in different sequences in each matrix segment. For example, in FIG. 19 the pairs of pitches could be arranged in any sequence, such as 41, 43, 42, 44, 46, 45; 41, 42, 43, 45, 46, 44; 43, 42, 41, 46, 45, 44, etc. No matter the sequence of the pitches 41-46, the length or circumference of any sequence of pitch lengths L41-L46 remains the same, namely, 11.061". Furthermore, no matter the sequence of the pitches, all abut at the pitch planes (generally P--P) and the tread patterns at all the pitch planes P--P are perfectly matched circumferentially, as is visually evident from FIG. 19, particularly relative to the planes Pu1--Pu1, Pu2--Pu2, PL4--PL4, etc.
It will now be assumed that the mold 10 is to be converted from the 421/4" tire diameter matrix 40 to a larger tire diameter matrix, for example, a tire diameter of 423/4". Obviously the bolts 157 are removed and each top sidewall plate 150 is also removed to expose the interior of each of the mold sections 12-15 and the segments 21-32 thereof, as is shown in FIG. 4. In order to reduce mold conversion time and associated down-time, it is obviously preferable to alter as few of the matrix segments 21-32 and the pairs of pitches 41-46 thereof, as is possible when converting from the 421/2" diameter matrix to the 423/4" matrix. With this in mind it is preferable to change only one matrix per mold section. Accordingly, it will be assumed that only one matrix segment 21-32 will be removed from each mold section 12-15, and also preferably an end matrix segment of each mold section is preferably removed because of ease and convenience. Accordingly, the matrix segments 22, 23 will remain in the mold section 12 and only the matrix segment 21 will be removed. Similarly, the matrix segments 24, 27 and 30 will be removed from the respective mold sections 13, 14 and 15 while the matrix segments 25, 26; 28, 29; and 31, 32 will remain in the respective mold sections 13, 14 and 15. Therefore, retained in the mold 40 and left unaltered are eight mold sections each having the earlier noted total length of 11.061" or a total of 88.488".
Each of the removed matrix segments 21, 24, 27 and 30 will necessarily have the clamp assemblies 35 loosened by appropriately unthreading the nuts 116 associated with the bolts 114. The pair of pitches 42 will be removed from the sequence of pitches 41-46 (FIG. 19) and substituted therefor is another pair of pitches 45. Therefore, the pairs of pitches in each of the matrix segments 21, 24, 27 and 30 are 41, 45, 43, 44, 45, and 46. Thus in each of the matrix segments 21, 24, 27 and 30, there are no longer a pair of pitches 42, and instead there are a pair of pitches 45 and the pitches 41, 43, 44 and 46. The total length of each segment 21, 24, 27, 30 is therefore the total of the lengths L41, L45, L43, L44, L45, and L46 which equals 11.4537" per matrix segment or a total of 45.8148". Adding 88.488" and 45.8148", the total is 134.3028" circumference which when divided by π is a tire diameter of 42.7499" or 423/4" diameter. Obviously, the nuts 116 are tightened, the matrix segments 21, 24, 27 and 30 are repositioned as shown in FIG. 4, and a molding, new tire treading or retreading operation can take place for a 423/4" diameter tire in, of course, the same mold 10. Furthermore, since the thread configuration 60 of the pitches 41-46 match across the pitch planes P--P, the pair of pitches 45 substituted for the pair of pitches 42 and sandwiched between the pairs of pitches 41, 43 match perfectly with the latter.
If it is desired to mold, tread or retread a tire of a diameter smaller than the original 421/4", this can be readily accomplished by again selectively changing the pitches 41-46. In this case it will be assumed that the mold 10 has the same pitches 41-46 as described for the 421/4" diameter matrix, namely, twelve identical pitches each totalling 11.061". Just as in the case of the 421/4" diameter tire, it will also be assumed that eight matrix segments 22, 23; 25, 26; 28, 29 and 31, 32 will not be changed thus retaining a total circumferential matrix length of 88.488". The four matrix segments 21, 24, 27 and 30 are again removed, the clamp assemblies 35 loosened, and in each segment 21, 24, 27 and 30 the pairs of pitches 43, including the upper pitch 43U and the lower pitch 43L, are removed and substituted for by a pair of pitches 46 resulting in a sequence of pitches of 41, 42, 46, 44, 45 and 46 for each of the four segments 21, 24, 27 and 30. The lengths of each segment following this substitution is the total of L41, L42, L46, L44, L45 and L46 or a total of 10.683" per matrix segment and 42.6732" for the four matrix segments 21, 24, 27 and 30. The total of 88.488" and 42.6732" is 131.1612" circumference which when divided by π is 41.7499" or 413/4" tire diameter.
It is again emphasized that though the tire circumference and diameter has again been changed, the tread pattern or configuration 60 matches across all pitches at each pitch plane P--P. The latter also applies irrespective of the sequence of the pitches, as was earlier noted. In other words, in the last example the pair of pitches 43 was removed and replaced or substituted for by another pair of pitches 46. Thus the sequence of the pitches became 41, 42, 46, 44, 45 and 46. However, the sequence could as well be 41, 46, 42, 44, 45, 46; etc. Again, no matter the sequence of the selected pitches, all tread configurations of the tread pattern 60 match across the pitch planes P--P of adjacent pitches 41-46.
Though three examples have been given exemplary of the invention, these should not be considered limiting since numerous different diametered tires can be molded by selecting appropriate pitches 41-46. Table I lists hereafter diameters increasing and decreasing in 1/8" increments from the median mold diameter of 42 1/4" diameter which allows new tires or retread tires in the range of 41-431/2" to be molded in the mold 10.
TABLE I______________________________________MOLD CAVITY/TIRE DIAMETERS ATTAINABLEIN MEDIAN 421/4" MATRIX DIAMETER (INCHES) CIRCUMFERENCE (INCHES)______________________________________MAXIMUM 43.5 136.659 43.375 136.266 43.25 135.874 43.125 135.481 43 135.088 42.875 134.696 42.75 134.303 42.625 133.910 42.5 133.518 42.375 133.125MEDIAN 42.25 132.732 42.125 132.229 42 131.947 41.875 131.554 41.75 131.161 41.625 130.768 41.5 130.376 41.375 129.983 41.25 129.590 41.125 129.198MINIMUM 41 128.805______________________________________
Table II is exemplary of common tires falling in the 41" to 431/2" diameters.
TABLE II__________________________________________________________________________ DIAMETER TIRE TREAD WIDTHSIZE TYPE PR AT 16/32 MOLD CS TIRE MOLD__________________________________________________________________________TREAD DIAMETERS FROM 41" to 411/2"11R22.5 X 14 41-413/8 411/4 10.6-11.5 7.6-8.5 81/811R22.5 X 16 411/4-411/2 411/2 10.6-11.2 7.4-8.7 81/8275/80R24.5 PX.sup. 14 41-411/4 411/4 10.7-11 7.7-8.5 81/810R22.5 X 14 411/8-411/2 411/4 10.6-11.1 7.6-8.5 71/2-81/810R22.5 X 16 411/4-411/2 411/2 10.6-11.3 7.4-8.7 71/2-81/810.00R20 X 14 411/8-411/2 411/4 10.7-10.9 7.2-8 71/2-81/810.00R20 X 16 411/4-411/2 411/2 10.7-11.8 7.1-8.7 71/2-81/8295/80R22.5 PX.sup. 16 413/8 411/2 11.7 8.5 81/8TREAD DIAMETERS FROM 421/4" to 423/4" 11.00R20 X 14 421/2 421/2 11-11.4 7.7-8.1 71/2-81/811.00R20 X 16 421/2 423/4 11-12 7.7-9.2 81/810.00R22 X 14 421/2-425/8 423/4 10.6 7.9 71/2-81/812R22.5 X 16 421/2-425/8 423/4 11.2-11.3 7.6-8 71/2-81/8TREAD DIAMETERS FROM 431/4" to 431/2"10.00R22 X 12 431/8-433/8 431/4 10.7-10.9 7.4-7.9 71/210.00R22 X 14 431/4-433/8 431/2 10.6-11.3 7.4-8.7 71/2-81/811R 24.5 X 14 431/8-433/8 431/4 10.9-11.1 7.6-8.5 71/2-81/811R24.5 X 16 433/8-431/2 431/2 10.7-11.1 7.6-8.7 71/2-81/8__________________________________________________________________________
The mold 10 is also capable of molding new or retread tires of varying tread widths, including tread widths beyond those listed in Table II. In order to do so, one or more circumferential pitch inserts 250 (FIG. 27) are provided which have spaced generally parallel circumferential surfaces (unnumbered) provided with an arcuate groove 251 and an arcuate rib 252 which mate with the respect ribs 141 and grooves 142 of the pairs of pitches 41-46 and specifically the upper pitches 41U-46U and the lower pitches 41L-46L. An inner circumferential surface 253 of the pitches 250 has a tread configuration corresponding to that of the tread configuration 60, and preferably all the pitches 250 have parting planes P--P and dimensions corresponding to and mating with those of the pairs of pitches 41-46. The latter results in the pitch inserts 250 matching across all pitch planes, particularly radial pitch planes corresponding to the pitch planes P--P of FIG. 19. By utilizing such pitch inserts 250 tires can be molded or retreaded having appreciably wider tread widths, as represented in Table III listed hereafter.
TABLE III__________________________________________________________________________PITCH INSERT(S) FOR WIDE TREADS DIAMETER DIAMETER SPACERTIRE SIZE TYPE PR TIRE MOLD CS TIRE MOLD WIDTH__________________________________________________________________________13.80R20 PX 18 41 41 12.6 9.8 91/2 2"315/80R22.5 PX 18 423/8 421/2 12.4 9 9 11/2"315/80R22.5 PX 20 421/4 421/2 12.4 9.3 9 11/2"385/65R22.5 .sup. X 18 42 42 14.9 11.1 11 31/2"__________________________________________________________________________
Though the invention has been thus far described relative to an annular mold or molding machine 10, the invention is equally applicable to a relatively long and flat mold, as is generally designated by reference numeral 270 in FIGS. 28-30. In this case the mold 270 includes opposite generally parallel longitudinal walls 271, 272 and opposite shorter end walls 273, 274 rigidly interconnected in surrounding confining relationship to pairs of pitches 241-246 which are essentially identical in construction to the pitches 41-46, respectively, including the matching of the tread configuration or profile 260 across the individual pitch planes P241, 242-P241, 142; P242, 243-P242, etc. Furthermore, a pitch insert 250' (which is not used for narrower treads) is sandwiched between the pairs of pitches 241-246 and locked thereto by bolts and nuts 262, 263 in the manner clearly apparent from FIG. 30 of the drawings. The mold 270 is heated by steam heaters 280, 281, the lower one of which is bolted to the walls 271-272 and the upper one of which is removably secured to the same walls to form a generally uniplanar length of rubber, specifically "precure," which after molding is removed from the mold 270, transversely cut into desired lengths, and applied to the circumference of buffed tires. Heretofore when such precure was made in long lengths and cut into shorter lengths, the splices did not match even with stretching or crowding the rubber, except rarely by happenstance, and therefore tires were unsightly and were difficult to balance. However, in keeping with the present invention, a relatively long length of precure can be formed in the mold 270, transversely severed along any one of the parting pitch planes (generally) P--P, and all splices, irrespective of the length, would match.
As an example, it will be assumed that a length of precure is to be molded in the mold 270 sufficient to apply a tread to each of three tires with the tires varying in diameter from 41" to 431/2" which, of course, reflects a difference in length of approximately 21/2". The mold 270 is primed in FIG. 31 to designate changes in mold length and pitch organization/juxtaposition as compared to the mold 270 of FIGS. 28-30. However, the pitches 241-246 are assembled in the mold 270' in abutting relationship and clamped therein by the bolts 262 and nuts 263 as in the manner heretofore described. The major difference between the mold 270 and the mold 270' is the fact that mold 270' has a mold or matrix cavity 260' having an overall length of 407.19". The length of 407.19" is selected because one-third thereof, minus one or more pitches, as necessary, will produce three pieces of precure (hereinafter precure segments) each of which will generally "fit" an associated tire circumference in the diameter range from 41" to 431/2" with either no stretch or minimum stretch. (Precure tread can be stretched a minimum of one inch around a tire circumference, and therefore it is not necessary for the matrix cavity 260' to be exactly three times the circumference of the three tires which are to be retreaded from the three precure segments cut from the single length of precure molded in the matrix cavity 260'.)
Turning specifically to FIG. 31, the mold 270' is fully illustrated and includes a cavity 260' which is 407.19" in length, as aforesaid, and includes three identical sections 301, 302 and 303. The entire mold cavity 260' is formed of thirty-six segments 501-536 or twelve segments per each section 301, 302 and 303. The section 301 is formed of the segments 501-512, the section 302 is formed of the segments 513-524 and the section 303 is formed of the segments 525-536. The total length of each section 301, 302 and 303 is identical, namely 135.73" (1/3 of 407.19") which is accomplished by selectively assembling and juxtapositioning the pitches 241-246.
Each of the segments 501-511; 513-523 and 525-535 of the respective sections 301, 302 and 303 is of identical lengths and each is formed of the pitches 241, 246, 244, 245, 243 and 242 in this exact order from left-to-right in FIG. 31. The pitch 241 is 2.2853", the pitch 246 is 1.6962", the pitch 244 is 1.5981", the pitch 245 is 1.8926", the pitch 243 is 2.0889"and the pitch 242 is 1.4999". The total length of these six pitches is 11.061" which multiplied by eleven segments is 121.67". Accordingly, the total length of each of the segments 501-511; 513-523 and 525-535 is 121.67".
The final segment 512, 524 and 536 of each respective section 301-303 is also of an identical length and is formed by the pitches 243, 246, 244, 243, 246, 245, 242 and 242 in exactly that order from left-to-right in FIG. 31. (However, for purposes of describing the method of cutting the mold precure into three precure segments, the last two pitches of the segments 512, 524 and 536 have been numbered 242a, 242b; 242c, 242d; and 242e, 242f, respectively. Therefore, the total length of each segment 512, 524 and 536 is 14.06". Each segment 301, 302 and 306 therefore totals 121.67" (eleven segments) plus 14.06" (one segment) or a total of 135.73" which when multiplied by the three sections 301-303 is a total length of 407.19".
TABLE IV__________________________________________________________________________SINGLE PRECURE MOLD LENGTH FOR RETREADINGTHREE TIRES OF DIFFERENT DIAMETERS/CIRCUMFERENCESTIRE TIRE PRECURE PRECURE PITCH PLANES/ PRECUREDIAMETER CIRCUMFERENCE LENGTH SEGMENT LENGTH PRECURE CUT PLANES SEGMENT__________________________________________________________________________ STRETCH431/2" 136.66" 407.19" 135.73" 242b of segment 512 0.93" 242d of segment 524431/4" 135.87" 407.19" 135.73" 242b of segment 512 0.144" 242d of segment 524423/4" 134.3" 407.19" 134.23" 242a/242b of segment 0.069" 242c/242d of segment 524 242e/242f of segment 536421/4" 132.73" 407.19" 132.73" 245/242a of segment 0.0 245/242c of segment 524 245/242e of segment 536411/2" 130.37" 407.19" 130.24" 246/244 of segment 0.1214 242a/242b of segment 512 246/244 of segment 513 242c/242d of segment 524 246/244 of segment 525 242e/242f of segment 53641" 128.80" 407.19" 128.65" 244/245 of segment 501 242a/242b of segment 512 244/245 of segment 513 242c/242d of segment 524 244/245 of segment 525 242e/242f of segment__________________________________________________________________________ 536
Reference is made to Table IV from which it can be seen that a 431/2" diameter tire has a circumference of approximately 136.66". Thus, if the precure from the matrix cavity 260' of FIG. 31 is cut through the pitch plane of the pitch 242b of the section 512, and the pitch plane 241 of the section 513, and also cut through the pitch plane of the pitch 242d of the segment 524 and 241 of the segment 525, three precure segments will be produced, each having a length of 135.73". Therefore, each 135.73" length of precure segment need be stretched but 0.93" to accommodate a 136.66" circumference of a 431/2" diameter tire which is easily accommodated since the precure segment of 135.73" can readily be stretched a minimum of 1" (or more). Thus, the stretch of 0.93" per 135.73" of precure segment is virtually negligible and permits each length of precure segment to be applied evenly to an associated tire of 431/2" diameter in the absence of heavy spots or gaps between the precure tread and the buffed tire and, most importantly, with perfect matching across the splice of each precure segment because, of course, the cutting across or through the pitch planes latter-described is across tread configuration of the matrix cavity 260' which matches across these pitch planes. In other words, the precure segment of the section 301 would be spliced at the plane of the pitch face 242b of the segment 512 which would match the tread configuration across the pitch face of the pitch 244 of the segment 501. Similarly, the precure segment corresponding to the section 302 would be spliced across the abutting pitch faces of the pitch 242d of the segment 524 and the pitch face of the pitch 241 of the segment 513.
Assuming a 431/4" tire is to be retreaded, Table IV indicates that a tire of this diameter has a circumference of 135.87". Accordingly, the exact precure segment lengths (135.73") are utilized and the precure is cut exactly as that described relative to the 431/2" diameter tire. However, in this case when the precure lengths are each applied to the circumference (135.87") of a 431/4" diameter tire, each would have to be stretched 0.144", again, a very moderate and acceptable distance.
In the case of a 423/4" diameter having a circumference of 134.3" (Table IV), the 407.19" total precure length is cut into three segments each having a length of 134.23". This is accomplished by cutting the total length of precure in exactly the same manner as described relative to the 431/2" and/or 431/4" tire diameters resulting in three precure lengths of 135.73". Each of these precure segments is then cut across a pitch plane corresponding to the pitch planes between the pitches 242a, 242b of the segment 512, the pitch plane between the segments 242c, 242d of the segment 524, and the pitch plane between the pitches 242e, 242f of the segment 536. This effectively removes a piece of precure corresponding to the pitches 242b, 242d and 242f, each having a length of 1.4999". Subtracting 1.4999" from 135.73" is approximately 134.23" per length of precure segment cut from the corresponding mold precure sections 301, 302 and 303. Each precure segment 134.23" is therefore extremely close to the 134.3" tire circumference requiring only a very modest stretch of 0.069" per tire circumference. Obviously, there is also a loss of approximately 4.5" of precure (total of 242b, 242d and 242f), but this is minimal when compared to the fact that a single mold 270' is all that a retreader requires to mold precure to retread numerous different diametered tires.
In order to retread a 421/4" diameter tire having a 132.73" circumference, a precure segment of 132.73" is obtained from each section 301, 302, 303. In this case the total precure length is cut as was described relative to the 431/2" or 431/4" tire diameters, but now the precure segments are cut along pitch planes corresponding to the pitch plane between the pitches 242a, 245 of the segment 512; 242c, 245 of the segment 524 and 242e, 245 of the segment 536. This effectively removes approximately 3" from each precure segment, namely, the total length of the pitches 242a, 242b; 242c, 242d and 242e, 242f per section 301, 302, and 303, respectively. Therefore, 135.73" reduced by 3" is 132.73" per precure segment which corresponds exactly to the circumference of a 421/4" diameter tire which obviously means there is no stretch involved at the splice of each tire.
A 411/2" tire has a circumference of 130.37", and in this case the total precure segment length (407.19") is cut as follows: The precure length is cut at the pitch plane between the pitches 246, 244 of the segment 501 and between the pitches 242a, 242b of the segment 512. This effectively removes the total length of the pitches 242b, 241 and 246 which achieves a length of 130.24" for the precure segment 301 which in turn requires 0.1214" of stretch. The precure is also cut as further set forth in Table IV to achieve two other precure segments corresponding to the sections 302, 303, each of 130.24".
In the final example, the 41" diameter tire has a 128.8" circumference which is best matched by a precure segment having a length of 128.65" which is achieved by cutting the precure as set forth in Table IV resulting in each precure segment having a length of 128.65" requiring a stretch of 0.146" per tire circumference. This obviously removes a piece of the total precure corresponding to the length of the pitches 241, 246 and 244 of the segment 501 and the pitch 242b of the segment 512, which is a total length of 7.08". The precure of the other mold sections 302, 303 is cut along corresponding pitch planes resulting in the formation of three precure segments each of approximately 128.65" necessitating not only a stretch of a nominal 0.146" but also a loss of approximately 21" of precure. However, even 21" of precure loss is far outweighed by the tread matching heretofore noted and the minimal investment involved in the utilization of essentially a single mold 270' and a series of specifically utilized pitches 241-246 to achieve a single length precure (407.4") which through selective pitch plane cutting achieves multiple diameter/circumference tire retreading with tread matching at all splices. Gaps and excessive tension at each retread splice, as is now conventional, is completely eliminated, as is excessive stretching. Presently when conventional precure is excessively stretched, the ends stretch more than the middle causing a thin section of tread adjacent the splice. Normally, the precure is also thicker diametrically opposite the splice. Therefore, excessive stressing occurs in the area of the splice and there is excessive rubber remote therefrom. Furthermore, if the precure is too long it will crowd or bulk at one or more portions along the tire circumference which results in one or more humps, and these are usually accompanied by a weak bond between the buffed tire and the precure tread. Obviously any one of these problems can provide balancing and alignment difficulties, but all are essentially entirely eliminated by the present invention.
In further accordance with this invention, a full circle curing tube or a curing bladder can be inserted in the tire T (FIG. 3) and pressurized to urge the new rubber on the tire T into intimate engagement with the tread configuration 60 of the mold cavity 40. A typical bladder of this type is fully disclosed in U.S. Pat. No. 3,990,821 in the name of Kenneth T. MacMillan mentioned earlier herein. Furthermore, the apparatus 10 can be used to manufacture annular precure, as opposed to retreading the tire T. In this case an annular piece of rubber or like material is inserted into the mold cavity 40 when the mold sections 11-14 are opened, after which the latter are closed and a precure curing tube (not shown) located between the annular piece of rubber and the hub 50 is inflated to force the precure radially outwardly into intimate engagement with the mold cavity configuration 60. Subsequently the mold sections 11-14 are opened and the annular precure is removed therefrom. If the precure has a circumference of 132.73" (see Table IV), it will match a 421/4" diameter tire and need but be stretched slightly, the tire encircled thereby, and subsequently cured thereto in a conventional manner. If, however, the circumferential length of the annular precure is 135.73" or 134.23" (see Table IV), the annular precure can still be stretched well beyond the 0.93", 0.144" and 0.069" to accommodate tire diameters of 431/2", 431/4" and 423/4", respectively. Just as obviously, any of the annular precure segments can be cut across the pitch planes thereof in the manner heretofore described, and an appropriate piece of precure removed, and the remaining precure length encircled about and/or stretched relative to an associated buffed tire, spliced, and cured thereto. The cutting and matching of an annular precure corresponds identically to that heretofore described more specifically which is hereat incorporated by reference in order not to unduly length this record.
Though the apparatus and method described relative to FIG. 31 and Table IV dealt with cutting a precure of 407.19" length into three precure segments each of the same length, it is also within the scope of this invention to cut the total length (407.19") of precure into a variety of lengths to fit any combination of three tires of equal or different diameters, as are set forth in Table IV. For example, if one were interested in retreading three tires of 431/2", 431/4" and 423/4", two of the precure segments would be cut to 135.73" and the third precure segment would be cut to 134.23". The two larger precure segments would be used to retread the 431/2" and 431/4" diameter tires while the smaller precure segment would be used to retread the 423/4" tire (see Table IV).
It is also in keeping with the present invention to construct a mold which would have a total length of only one of the sections 301, 302 or 303. A precure from one of these molds would be 135.73" long and would, of course, fit any of the tires of Table IV. Thus, a press or platen 135.73" (11' 33/4") long could be used to make three separate precure segments each 135.73" long and, if cut across the pitch planes (or not), the effect of three such precure segments formed in an individual shorter press one-third the length of the platen 270' effectively produces three separate precure segments which collectively total 407.19". A platen/press of this lesser one-third length would be obviously more inexpensive to build, easier to load and unload, shorter precure segments produced thereby would be easier to handle, and would be perhaps more cost effective in a low demand retread operation.
Although a preferred embodiment of the invention has been specifically illustrated and described herein, it is to be understood that minor variations may be made in the apparatus and the method without departing from the spirit and scope of the invention, as defined in the appended claims. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a focusing module for use with a divergent light source, and more particularly, the invention relates to a focusing module for a laser diode which can be adjusted to focus the output of such a diode prior to being affixed in a permanent focused position.
2. Description of the Prior Art
Various means for generating a laser beam are known in the prior art and may include a light source such as a laser tube or a semiconductor laser diode of a continuous wave or pulse type. A laser diode is much smaller in size and lighter in weight relative to a laser tube and therefore is particularly desirable for applications where size and weight requirements are to be minimized. One such application is a small, light weight hand held bar code scanner such as that described in U.S. Pat. No. 4,496,831. However, laser diodes emit a beam of light which diverges as the light moves outwardly along a centralized axis of emission. Typical laser diode light diverges 10°-20° in one plane through the axis of emission and 40°-50° in a second plane through the axis of emission normal to the first plane. The axis of emission is defined as the axis around which the light diverges symmetrically.
Such angular divergence is unacceptable for bar code scanning applications, which require a beam spot, preferably rectangular in cross-section having a relatively well defined edge. To achieve such a beam spot with the light of a laser diode, the divergence must be reversed using a lens system, thereby converging or focusing the light's intensity to a well defined spot at the point at which the bar code is to be read.
In the prior art, such lens systems for converging and focusing emitted laser diode light were embodied in one of a series of co-axial cylindrical members, one of which received the laser diode and was affixed thereto. The member remote from the diode was closed, having a circular opening therein which was coaxial with the emission axis of the diode and the central axis of the member supporting the diode. This opening allowed emission of the now converging beam, which was focused by the lens at a position located a distance from the emitter of the diode along the above axis. The lens was mounted in the member remote from the diode. Motion of the lens in the axial direction was prevented by providing a force such as from a compressed spring which extended the interior length of the two members and was coaxial with the central axis the cylindrical members, where one end engaged the lens and its opposite end rested on the washer-like face which defined the emission aperture of the received laser diode.
Movement in the axial direction was permitted through a construction whereby the members were provided with threaded portions on the interior or exterior surface which contacted the other member and interfaced with the corresponding threaded portion on the surface of the other member. These threads allowed one member to be rotated with respect to the other, changing their relative positions along the central axis, and consequently moving the lens system along the central axis with respect to the laser diode. Therefore, by rotating the cylindrical members with respect to one another, the focus of the laser light was adjusted.
The lens system of the prior art suffered from a number of disadvantages, with one such disadvantage being the cost of the focusing module. Due to the threads required on the members to focus the laser light and permit axial movement between the cylindrical members, the cylindrical members had to be precisely machined, which is relatively expensive with respect to other metal working techniques and which consequently increased the cost of the end product in which the focusing module was used.
Another disadvantage in the prior art was that the lens was seated directly on a washer-like surface of one of the cylindrical members, which necessitated that this surface have a forward taper to match the portion of the profile of the lens surface with which it contacted, in order to align and maintain a coaxial orientation of the lens axis with the central axis of the members. If the washer-like surface were normal to the annular portions, the seat would be made through contact with the innermost ledge of the washer, making the lens susceptible to tilting and chipping. On the other hand, a tapered surface provided a ring of contact by the seat, avoiding the above, but this taper required that the washer-like surface be machined off a right angle portion of the surface, resulting in a forward annular portion of relatively small radius. Therefore, the opening in the front of the cylindrical member was smaller than desirable, and served to mask the light which passed through the lens, decreasing the intensity of the focused spot. The intensity of the beam passing through the opening is critical in applications such as bar code scanning, wherein reliability is a function of the sharpness of the reflected light as well as the intensity. To compensate for this loss of intensity, the prior art focusing module had to be precisely aligned with respect to the emission axis, thereby achieving a more discretely focused spot at the point of scanning; however, this precision required the dimensional tolerances of the members of the focusing module to be very small, which could only be achieved by machining the critical dimensions at a high cost. Dimensions of the threaded interfaces were critical, and had to prevent even marginal axial and radial movement between the cylindrical housing members which would result in misalignment of the lens and decrease focusing of the emitted light, causing an asymmetrical intensity pattern at the point of focus.
A further disadvantage laid in that the opening of the focusing module for emission of laser light had to be circular by this design, since any other shape would not maintain its orientation with respect to the laser diode about the central axis after the cylindrical members were rotated in the focusing operation. Therefore not only was the focusing module opening circular, it had to be of small diameter, and had the further effect of limiting the focused intensity for the scanning operation.
A still further disadvantage was encountered during the focusing process, when one cylindrical housing member was rotated with respect to the other. Since the lens made direct contact with the rotating cylindrical member and the stationary spring, the lens rotated with respect to the cylindrical housing member, the positioning spring, or both. This relative rotation tended to misalign the central axis of the lens, and led to scratching or scoring of the lens as it moved relative to the housing member and spring.
SUMMARY OF THE INVENTION
The present invention eliminates or substantially ameliorates the disadvantages encountered in the prior art through the provision of a highly accurate focusing module of relatively simple and inexpensive contruction.
It is an object of the present invention to provide a relatively inexpensive and lightweight focusing module for a divergent light source such as a laser diode.
Another object of the present invention is to provide a focusing module of successively received cylindrical housing members which focuses without rotating the members with respect to one another about their central axis.
A further object of the present invention is to provide a focusing module where the lens glass does not rest directly upon the lens holder of the focusing module.
A still further object of the present invention is to provide a focusing module where the cylindrical members permit focusing and are secured together in a focused position, the constructional tolerances between the members being such so as to allow the members to be spin formed, rather than machined.
Yet another object of the present invention is to provide a focusing module where the members are constructed to allow the angular alignment of the focusing lens to be marginally adjusted so that its center axis is coaxial with the center axis of the divergent light thereby allowing a focus of symmetric intensity.
Another object of the present invention is to provide a focusing module where the converging light emitting from the focusing module passes through an opening having a shape and orientation conforming to the cross section of the emitted beam, and whose radial orientation with respect to the emission axis remains constant during focusing.
Consistent with these objectives and in accordance with the present invention, a focusing module particularly adapted for use with a laser diode comprises:
(a) A cylindrical diode holder having a first annular portion for receiving a laser diode, adapted to center and receive the base therein and adapted to interface with the diode to prevent axial rotation of the diode with respect to the diode holder;
(b) A cylindrical lens holder adapted to slide axially within the diode holder, having an annual seating portion at a first end thereof, and adapted to interface with the diode holder at the opposite end thereof to prevent axial rotation of the lens holder with respect to the diode holder;
(c) An optical lens assembly particularly adapted for use with the laser diode, and being mounted within the annular seat defined by the first end of the lens holder; and
(d) A spring means for urging the lens assembly into engagement with the annular seat;
whereby the lens holder may be slid within the diode holder to focus the output of the laser diode through the lens assembly, and then be secured thereto in a focused state.
Since the emission of a laser diode has no unique focusing properties the focusing module described can be used generally with any divergent light source. The following discussion will focus on the laser diode as the focused source.
The cylindrical lens holder and diode holder can be made of any lightweight metal, such as brass, and may be shaped to provide the successive annular portions by spin forming. Other materials, such as some plastics, may also be formed into the requisite shape in an inexpensive manner. Therefore, relatively expensive constructional processes such as machining are not required.
The cylindrical lens holder and diode holder (collectively referred to as "cylindrical members") interface with a notch and key feature which runs in the direction of the central axis along portions of the cylindrical members. This feature prevents rotation of the cylindrical members with respect to one another about the central axis. A similar notch and key mechanism between the received portion of the base of the laser diode and the receiving diode holder prevents relative rotation about the central axis of the laser diode and the diode holder. Since the successive cylindrical members are interlocked, the complete focusing module cannot rotate with respect to the laser diode about the central axis, thereby enabling the opening at the front end of the focusing module to remain fixed with respect to the cross section normal to the central axis of the light emitted. Therefore, the opening of the focusing module may be cut in a shape corresponding to that of the cross section of the emitted light, allowing more light to be focused.
Focusing of the focusing module is achieved by sliding the lens holder with respect to the diode holder along the direction of the central axis. Again, relative rotation around the axis is not needed, and is in fact not possible due to the interlocking key features. The tolerances between the cylindrical members allow some angular adjustment of the central axis of the lens. When the desired focus is achieved, the members are permanently fixed relative to one another, which depending on the material of which the members are constructed, can be done in a number of ways using a variety of materials and methods, including adhering by adhesives such as glue or epoxy, fastening by staking, spot-welding, ultra-sonic welding, or the like.
The lens glass is surrounded and supported in an integral lens assembly, the lens assembly having torroidal shape with two portions of differing outer radii. The lens assembly makes contact with the seat at a washer-like surface of the lens holder and is supported at this point. Since this surface is flat and normal to the lens assembly's central axis, the lens seat need not be a tapered surface as in the prior art.
The lens assembly remains static with respect to the lens holder along the central axis of the lens holder due to a compressed positioning spring forcing it against the seat in the axial direction. Alternatively, the lens assembly may be adhered to the lens seat, eliminating the need for the spring. The spring interfaces at one end with the base of the laser diode and at the other with the lens assembly so that neither the lens nor the diode emitter are in danger of scratching or scoring during the focusing movements. The lens assembly is received in the smaller annular portion of the lens holder which extends forward from the washer-like seating surface. The lens assembly fits securely within the forward annular portion of the lens holder, thereby maintaining a coaxial relation between the central axis of the lens and the lens holder.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and other features of the invention will become more readily apparent and may be understood by referring to the following detailed description of a preferred embodiment of the focusing module, taken in conjunction with the accompanying drawings, in which:
FIG. 1a is a side sectional view of a focusing module mounted on the base of a laser diode, as embodied in the prior art;
FIG. 1b is a front view of the focusing module of FIG. 1a, taken along lines 1b--1b in FIG. 1a.
FIG. 2a is a side elevational view of a conventional laser diode;
FIG. 2b is a front view of the laser diode of FIG. 2a, taken along line 2b--2b of FIG. 2a;
FIG. 3a is a front view of a diode holder of a focusing module according to the present invention;
FIG. 3b is a side view of the diode holder of FIG. 3a, taken along line 3b--3b of FIG. 3a;
FIG. 3c is a partial side view of the diode holder of FIG. 3a, taken along line 3c--3c of FIG. 3a;
FIG. 4a is a front view of a lens holder of a focusing module according to the present invention;
FIG. 4b is a side sectional view of the lens holder of the focusing module, taken along line 4b--4b of FIG. 4a;
FIG. 4c is a front view of another embodiment of the lens holder similar to that of FIG. 4a;
FIG. 5a is a side view of the laser diode received within the positioning spring;
FIG. 5b is a front view of the laser diode received in the positioning spring of FIG. 5a, taken along line 5b--5b of FIG. 5a;
FIG. 6 is a partial sectional side view of the focusing module of the present invention showing the diode holder with the lens holder received therein;
FIG. 7 is a partial sectional side view of the focusing module of the present invention showing the diode holder and lens holder with the lens holder received by the lens holder; and
FIG. 8 is a cutaway side view of the operation of the completely assembled focusing module, with a laser diode mounted therein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in specific detail to the drawings, in which identical reference numerals identify similar or identical elements throughout the several views, in FIGS. 2a and 2b, there is shown a laser diode 20 which provides the divergent laser light to be focused by the present invention.
The laser diode 20 is a typical structure of laser diodes available commercially. Commercially available laser diodes structured in this manner include the Non-Contact L58300/L56100 by Sony or Toshiba, or the Non-Contact L58500 by Sony or Toshiba.
The dimensions given in the following description correspond to a particular representative embodiment of a focusing module, constructed according to the present invention, and are in no way to be considered as limiting. The dimensions given would enable the use of the focusing module with the above mentioned laser diodes.
Referring to FIGS. 1a and 1b, the laser diode 20 is shown with the prior art embodiment of a focusing module 10, having a threaded interface 11 between members 10A and 10B, which allows for focusing. The lens glass 18 is urged by a spring 19 to rest directly on the sloped seating portion 15 of member 10B, which is also provided with emission opening 17, circular in shape and of considerably smaller diameter than lens glass 18. Focusing of prior art module 10 is accomplished by rotation of member 10B with respect to member 10A.
FIGS. 3-8 show a particular embodiment of the focusing module of the present invention. As best shown in FIGS. 6-8, the focusing module 100 of the present invention has a diode holder 30, a lens holder 40, and a lens assembly 60 which seats at the front end of the interior of lens holder 40.
Referring to FIGS. 3a, 3b, and 3c, the diode holder 30 of the focusing module 100 is shown. The diode holder 30 is preferably of thin-walled construction as seen in FIGS. 3a and 3b, and has a first annular portion 35 and a second annular portion 31 of smaller radius than that of the first annual portion 35. In the representative embodiment, first annular portion 35 is on the order of 355 mil in inner diameter, and second annular portion 31 is on the order of 326 mil in inner diameter, both having a tolerance of approximately 1 mil.
The diode holder 30 and lens holder 40 are typically made of a light gauge metal, such as brass, and are preferably spin formed using standard spin forming and cutting techniques, but may also be formed by other known techniques such as drawing or stamping. These members 30 and 40 may also be molded of a light-weight rigid plastic material such as phenolic resins or other high impact plastics.
FIG. 3a shows a front or radial view of the diode holder 30 and demonstrates that the tubular shape of the diode holder 30 is primarily hollow. The thickness of the walls of the first annular portion 35 may be on the order of 6 mil, for example, and is therefore relatively thin compared to the diameter of the first annular portion 35. The cross-section shows the second annular portion 31 having a thickness likewise on the order of 6 mil and is therefore relatively thin compared to the diameter of the second annular portion 31. The first annular portion 35 and the second annular portion 31 connect through the sloping washer-shaped surface 33 whose radial surface has a width on the order of 6 mil and extends axially on the order of 20 mil.
Referring to FIG. 3b, in the representative embodiment the first annular portion 35 extends axially on the order of 125 mil, for example. The entire length of the diode holder 30 which is the net length of the first annular portion 35 and the second annular portion 31 is on the order of 325 mil.
Spaced equidistantly around the first annular portion 35 are a series of indentations extending radially inward, shown in FIGS. 3a, 3b, and 3c as a series of punches 34, 36, and 37. The punches 34, 36, and 37 are formed using standard shear or stamping technology, in which the shear portions 34a, 36a, and 37a, extend circumferentially along the rearward portion of the punch, shown most clearly by punch 36 of FIG. 3b. These shear portions 34a, 36a, and 37a further act as a stop to define the limit of reception of the base 21 of the laser diode 20 in the focusing module 100. To achieve proper axial orientation between the focusing module 100 and the laser diode 20 the distance between the shear portions 34a, 36a, and 37a and the rear axial end of the first annular portion 35 is uniform and is preferably equivalent to the axial length of base 21 of diode 20, and generally is on the order of 46 mil with a tolerance of 1 mil, in the representative embodiment.
The first annular portion 35 also has an inward indentation or groove 32 extending in the axial direction along the length of the first annular portion, as shown in FIGS. 3a-3c, and is best seen in FIG. 3c which clearly shows the groove 32 extending in the axial direction. The groove 32 extends radially inwardly so that its innermost extension has approximately the same radial distance as the inner radius of the second annular portion 31, the latter on the order of 326 mil. The groove 32 interfaces with a notch 24 shown in FIGS. 2a and 2b, extending in the axial direction of the length of base 21 of the laser diode 20 thereby preventing rotation of the diode 20 with respect to the center axis of the diode holder 30 when the diode 20 is received in the diode holder 30. Referring back to FIGS. 3a, 3b, and 3c, the inward groove 32 is stamped into diode holder 30 or pressed into the holder by a pressing operation.
Referring to FIGS. 4a, 4b and 4c, the lens holder 40 of the focusing module is shown, and as best seen in FIGS. 4a and 4b, the lens holder 40 has a flange portion 41, a rear annular portion 41A of radius smaller than the flange 41, and a forward annular portion 43 of radius smaller than the rear annular portion. The radially positioned washer-like surface connecting the rear annular portion 41A and the forward annular portion 43 forms the seating surface 42 for the lens assembly 60 as shown in FIG. 7 and described below. The front end of the lens holder 40 is a closed disk-like surface 44 with an opening 45 through which the laser light is emitted and which corresponds in shape to the cross-sectioned shape of the laser light beam. This shape is generally an oblong shape, such as but not limited to, an ellipsoidal shape. In FIG. 4a, three cuts 46, 47, and 48 in the flange 41, are shown and their function will be described below. In the projection along the center axis of FIG. 4a, the linear midpoint of these cuts is tangent to the outer surface of the rear annular portion 41A. This is also shown in FIG. 4b, where the cut 46 conforms the cut portion of the flange 41 and rear annular portion at the particular cross-section of FIG. 4b. The flange 41 further has a radially extending notch 49, which as seen in FIG. 4a, extends radially inwardly so that its innermost radial extension is approximately equivalent to the outer radius of the rear annular portion 41A. In a second embodiment of the lens holder 40 shown in FIG. 4c, the cuts 46, 47, and 48, and notch 49 may approach the washer-like surface projection but are not tangential to it.
The ellipsoidal opening 45 of lens holder 40 has its center point aligned with the central axis of the lens holder 40. The semi-major axis of ellipsoidal opening 45 bisects fitting notch 49 and also bisects cut 46 of flange 41 in the two dimensional projection in FIG. 4a. The semi-major axis of the ellipsoidal opening 45 in the representative embodiment may be approximately 160 mil and the semi-minor axis may be approximately 35-50 mil, depending on the particular laser diode used.
The lens holder 40 is received within the diode holder 30 as shown in FIG. 6. To achieve reception, the closed front end 44 of the lens holder 40 is moved coaxially into the radial opening of the diode holder 30 defined by the first annular portion 35 toward the radial opening at the opposite end of the diode holder 30 defined by the second annular portion 31. The rear annular portion 41A of the lens holder 40 has an outer radius only marginally smaller than the second annular portion 31 of the diode holder 30 thereby having a frictional engagement and maintaining the coaxial positioning of the diode holder 30 and the lens holder 40. The first annular portion 35 of the diode holder 30 receives the flange 41 (not shown in FIG. 6) of the lens holder 40. The flange 41 has radius marginally smaller than the radius of the first annular portion 35 thereby allowing reception. However, the flange 41 has radius larger than the second annular portion 31 of the diode holder 30 thereby preventing further reception in the axial direction of the lens holder 40 by the diode holder 30 when the flange 41 comes in contact with the washer-like surface 33 of the diode holder 30. The flange 41 freely travels in an axial direction past punches 34, 36, and 37 (not shown in FIG. 6) in the first annular portion 35 due to the cuts 46, 47, and 48 (not shown in FIG. 6) on the flange 41.
The received lens holder 40 is prevented from rotating about the center axis with respect to the diode holder 30 due to the notch 49 in the flange 41 of the lens holder 40 which interfaces with the groove 32 in the first annular portion 35 of the diode holder 30.
Referring again to FIGS. 4a, 4b, and 4c, the lens holder 40 has relative dimensions as defined above as well as the following for the representative embodiment: the thickness of the flange 41 rear annular portion 41A and forward annular portion 43 are on the order of 6 mil. The seating surface 42 has a surface width of approximately 37 mil, and a tolerance of approximetaly 1 mil. The seating surface 42 is normal to the central axis except for the bending at the point of contact with the annular portions 41A and 43. The inner diameter of the forward annular portion 43 is on the order of 250.5 mil, with a tolerance on the order of 1 mil. The outer diameter of the rear annular portion 41A is on the order of 324.8 mil with tolerance on the order of 0.5 mil. The outer diameter of the flange 41 is on the order of 352.5 mil with tolerance of the order of 0.5 mil. The length of the rear annular portion 41A is approximately 262 mil with a tolerance of approximately 1 mil. The length of the forward annular portion 43 is approximately 66 mil with a tolerance on the order of 1 mil.
Referring to FIGS. 5a and 5b, the positioning spring 28 of the focusing module 100 is shown interfacing with the base of the laser diode 20. The positioning spring 28 receives the cylindrical extension 22 of the diode 20. The positioning spring 28 has an unextended radius relatively smaller than the cylindrical extension 22; therefore the portion of the positioning spring 28 receiving the laser diode 20 provides an inward radial force on the base 21 of the diode 20 and the non-receiving portion of the positioning spring 28 tapers along its length. The positioning spring 28 receives the cylindrical extension 22 completely, so that one end of the positioning spring 28 rests on the ledge 23 of the base 21 of the laser diode 20.
FIG. 7 shows the lens assembly 60 of the focusing module 100 positioned in the focusing module 100. Shown in FIG. 7 is the lens holder 40 received in the diode holder 30 as described above with reference to FIG. 6. The focusing lens glass 63 is an integral part of lens assembly 60 and the central axis of the focusing lens 63 coaxially positioned with respect to the central axis of the lens assembly 60. Such lens assemblies are available commercially, and the model A-365 manufactured by Kodak is used in a preferred embodiment. The lens assembly 60 has an outer radius smaller than the rear annular portion 41A of the lens holder 40 but larger than the radius of the forward annular portion 43; the front face 64 of the lens assembly 60 rests upon the seating surface 42 providing an axial stop for the lens assembly 60. A ring extension 62 of the lens assembly 60 has outer diameter only marginally smaller than forward annular portion 43 thereby preventing radial movement of the lens assembly 60 with respect to the lens holder 40 and achieving a coaxial positioning of the focusing lens assembly 60, the diode holder 30, and lens holder 40.
Referring to FIG. 8, as described above, the diode holder 30 cannot rotate with respect to the received diode 20 and the received lens holder 40 cannot rotate with respect to the diode holder 30. Accordingly, the ellipsoidal opening 45 cannot be rotated axially with respect to the laser diode 20 and the cross-section of the emitted laser light approximately matches opening 45.
When the laser diode 20 is received in the focusing module 100, the positioning spring 28 is compressed against the lens assembly 60 forcing it in the axial direction against seating surface 42. The forward force against the seating surface is transmitted to the diode holder 30 at the washer-like surface 33 of the diode holder 30 by the flange 41 of the lens holder 40. This results in a forward axial force on the diode holder 30 with respect to the base 21 of the laser diode 20; therefore to receive the laser diode 20 in the diode holder 30, a force (shown as F1 and F2) is provided at the closed front end 44 to counteract this resulting force from the compressed positioning spring 28. When the force enables maximum reception of the base 21 of the laser diode 20 as defined by the punches 34, 36 and 37 on the first annular portion 35 of the diode holder 30, an adherent is applied at points where the base 21 of the laser diode 20 is received and allowed to cure, thereby affixing the base 21 of the laser diode 20 to the diode holder 30.
With the laser diode 20 affixed, the compressed positioning spring 28 forces forward axial movement of the lens holder 40 until the flange 41 rests on the washer-like surface 33 of diode holder 30. With the laser diode 20 energized, light emitted with an axial component passes through the lens assembly 60 and through the ellipsoidal opening 45. The focusing is adjusted by reapplying a force (shown in FIG. 8 as F1 and F2) at the closed front end 44 of lens holder 40, thereby sliding the lens holder 40 and lens assembly 60 in a rearward axial direction with respect to the diode holder 30. When focusing is achieved, forces F1 and F2 may be adjusted slightly due to the tolerances in the cylindrical members, which causes the central axis of the lens to be concentrically aligned with the central axis of the light emission, thereby achieving a symmetric intensity pattern. Once achieved, adherents such as described above are applied at points where the diode holder 30 and the lens holder 40 contact, and allowed to cure before the force is removed so that precise focusing is maintained. | 4y
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The present invention relates to a gas turbine engine, in particular in the aviation field, and has as its object the installation of a rotor shaft inside the engine.
BACKGROUND OF THE INVENTION
The operations of installing and removing a turbine engine are awkward, because of the number of parts that they comprise and the small clearances between them while the dimensions may be considerable. The cost of the working on the engine comprising such operations is therefore always high. The aim is therefore constantly to simplify them. In a front, double-bodied turbofan engine, such as the cfm56 engine, access to the bearing supporting the high pressure compressor shaft is particularly difficult because it is installed, on the intermediate casing, behind the fan and the first two bearings supporting respectively the low pressure compressor shaft and that of the fan. The intermediate casing is the portion of the casing of the machine that supports in particular the front rotor bearings. In order to avoid dismantling the whole front portion of the engine and the fan in particular, the elements of this bearing are currently arranged so as to allow installation from the rear. Such a solution is advantageous, but still has some disadvantages that it would be desirable to eliminate.
DESCRIPTION OF THE PRIOR ART
FIGS. 1 and 2 are reminders of a solution corresponding to the teaching of the prior art. The whole engine is not shown; only the immediate environment of the bearing is visible. The front and rear are defined relative to the direction of travel of the engine. A portion of the fixed structure of the intermediate casing 2 can be seen; the HP compressor shaft ball bearing 3 is supported by its outer race in this fixed structure. The bearing provides rotational support for the front end of the HP compressor shaft 4 whereof the trunion 4 ′ and a rotor disk 41 ″ are seen. The bearing supports, at the front, a bevel pinion 5 which drives the pinion 5 ′ connected to a radial shaft and forming the gearbox called IGB from which the auxiliary equipment is driven: pumps, electric current generators or other equipment. For this purpose, the bevel pinion 5 meshes with the pinion of the radial transmission shaft that is housed in one of the radial arms of the intermediate casing to drive the pinions of the accessory gearbox, known as the AGB. The bevel pinion is fixedly attached to the cylindrical coupling supported by the bearing.
To keep the shaft 4 in the bearing 3 , according to the teaching of the prior art, a nut 6 is provided that is held inside the pinion 5 , upstream by a segment or retaining ring 6 ′. The nut comprises a thread on its outer surface by which it is screwed into the upstream end of the shaft 4 , provided with an appropriate thread. A nut-lock 6 ″ keeps the nut in place in the shaft 4 . Furthermore, the axial splines on the inner wall of the coupling of the pinion 5 interact with splines on the outer surface of the shaft 4 to prevent any rotation of one relative to the other. This assembly incorporates the function of auto-extraction of the HP compressor. The function is performed by the segment which axially fixedly attaches the bearing nut to the bevel gear. Thus, by tightening the nut in the thread of the HP compressor shaft, the compressor is docked with the bearing; conversely, by unscrewing the nut, the compressor is pushed rearward because the nut is immobilized axially by the segment.
FIG. 2 shows the bearing of the shaft 4 before installation. The nut, placed in front of the bearing is first installed on the pinion before any installation of the elements from the rear of the intermediate casing. To prepare the installation of the shaft 4 , the bearing 3 needs to be heated at C in order to expand it and minimize the shrink-fitting forces. To avoid heating the nut 6 and to minimize the frictions in the thread when it is to be tightened onto the shaft 4 , there is a heat protection P around the nut. However, this protection is awkward to apply. It cannot be installed effectively.
The applicant has set itself the objective of preventing the problems associated with this installation.
SUMMARY OF THE INVENTION
More particularly, the problem to be solved relates to a type of connection between the HP compressor and the engine IGB making it possible to install and remove the HP compressor with sole access by the tools via the rear of the engine.
According to the invention, the system for attaching the end of a gas turbine engine shaft engaged inside a coupling supported by a bearing, by means of a nut, is characterized in that the nut comprises a first thread, by which it is screwed into said shaft comprising a thread, and a second thread by which it is screwed to said coupling comprising a thread. More particularly, the two screw pitches of the nut are reversed relative to one another so as to form an adjusting nut.
The solution of the invention is therefore suitable for installing the HP compressor shaft of a double-bodied engine whose power offtake to drive the machines' gearbox is provided by a bevel pinion fixedly attached to the latter, the coupling belonging to this drive bevel pinion.
The use of an adjusting nut allows the HP compressor to be removed simply, by working only from the rear of the engine, and is not compromised by the tools and installation means currently used.
Installation/removal via the rear of the engine is a very major advantage for this type of engine and greatly reduces the cost of such an operation.
In addition, the solution is compact; it fits into the available space and does not interfere with the air circulation between the IGB and the LP shaft. The present application also relates to a compressor and a turbine engine incorporating the system of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail, with reference to the appended drawings in which:
FIG. 1 represents, in axial section, a partial view of an installation solution corresponding to the teaching of the prior art;
FIG. 2 shows the elements of FIG. 1 pre-assembled and before the HP compressor shaft is installed;
FIG. 3 represents, in axial section, a partial view of a system for attaching the end of the HP compressor shaft according to the invention;
FIG. 4 shows the first step of the installation seen from the IGB side;
FIG. 5 shows the first step of the installation seen from the HP compressor shaft side;
FIG. 6 shows the second step with the docking of the compressor shaft;
FIG. 7 shows the engagement further forward of the compressor shaft;
FIG. 8 shows that the tightening of the adjusting nut on the coupling of the bearing is complete and that a nut-lock has been put in place.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 and following show an embodiment of the solution of the invention. The bearing 3 remains unchanged relative to the prior art as does the intermediate casing 2 . The upstream end of the shaft 14 comprises, as in the solution of the prior art, an inner thread 14 f interacting with a first outer thread 16 f 1 of a nut 16 . This nut 16 is cylinder-shaped and connects the shaft 14 to a bevel gear 15 . The bevel gear 15 comprises a bevel pinion 15 1 for driving the IGB. It also comprises a cylindrical coupling 15 4 shrink-fitted onto the inner race 3 i of the bearing 3 . At the front, the gear 15 is fixedly attached here to a labyrinth seal element 15 2 . Splines 15 3 are made inside the bevel gear to interact with splines 14 3 on the trunion 14 and keep them fixedly attached in rotation. The gear 15 also comprises an inner surface portion with a thread 15 f with which the cylindrical nut 16 interacts via a second thread 16 f 2 . The two threads 16 f 1 and 16 f 2 on the outer face of the nut 16 have reversed pitches as explained below.
FIG. 4 shows the bearing 3 with the bevel gear installed on the inner race 3 i of the bearing 3 and a heating means C′ indicated by wavy lines.
A description will now be given of the front installation of the HP compressor shaft in the bearing 3 , with reference to FIG. 4 and following.
The bearing is assembled with the bevel gear 15 shrink-fitted into the race 3 i of the bearing. The first step consists in heating the bearing 3 by placing a heater under the race 3 i . The advantage of the solution of the invention is already seen because, in the absence of a nut, no superfluous heating damages the surrounding parts.
In parallel, the nut 16 is placed on the shaft as shown in FIG. 5 . The thread 16 f 1 of the nut is engaged in the inner thread 14 f of the shaft 14 , over a predetermined length in order to have a correct final installation.
FIG. 6 shows that the shaft has been engaged in the bearing from which the heater has been removed and which is in the expanded state. The nut 16 has been screwed sufficiently onto the shaft 14 for it to butt against the thread 15 f of the bevel gear 15 , just after beginning to engage the axial splines between the shaft and the bevel gear arranged to allow a good angular indexation between these two parts, necessary for the lubrication of the bearing 3 to operate correctly. The operator begins to tighten the nut 16 in order to engage the thread 16 f 2 in the thread 15 f . Since the pitches of the threads 16 f 1 and 16 f 2 are reversed, tightening the nut progressively inserts it into the gear 15 that has been immobilized in rotation by an appropriate means that cannot be seen. Furthermore, since the splines 15 3 of the gear 15 and 14 3 of the shaft are engaged in one another, the shaft 14 is prevented from rotating on itself. The rotation of the nut also causes the shaft to advance inside the bearing 3 .
FIG. 7 shows that the shaft 14 has traveled further, until its front edge 14 5 comes into engagement in the corresponding shrink-fitting zone 15 5 inside the gear 15 . This shrink-fitting zone makes it possible to ensure that the bevel pinion 15 1 of the gear 15 is effectively supported by the shaft 14 .
With reference to FIG. 8 , it can be seen that the shaft is now butting against the part forming the rear labyrinth that is pressing on the inner race of the bearing 3 . A nut-lock 17 has been installed. It comprises elastically deformable branches 17 1 which fit into a recess 14 6 made in the shaft 14 . This figure shows the presence of the front portion 15 2 of the bevel gear that forms, with a scoop 15 5 , a surface for receiving oil for lubricating the pinion 15 1 and the bearing 3 . The oil delivery nozzle is not shown. This oil collected by the scoop 15 5 is guided through the longitudinal channels 15 6 and the splines 15 3 and 14 3 toward the bearing 3 that is provided with appropriate and known orifices for lubricating the balls.
The nut 16 may be called an adjusting nut because a tractile tension is applied to the shaft 14 . The nut is rotated by known tools across the shaft from the rear in particular. To prevent forces from passing through the bearing, the bevel gear may be axially strapped by means of an appropriate tool that is placed, for example, in an axial strapping zone made between tenons 15 7 made at the front of the gear to prevent any rotation during the installation and a shoulder 15 8 . | 4y
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FIELD OF THE INVENTION
[0001] The present invention is useful in the field of semiconductor processing. More specifically, the present invention discloses a method of depositing materials onto a substrate.
BACKGROUND
[0002] Semiconductor devices contain transistor elements and conductive lines of metal integrated with one another on a semiconductor substrate. In terms of location, the transistor elements are at the bottom of the device, so that they may be in direct contact with the underlying semiconductor substrate. Metal contacts electrically couple the transistor elements with the first level of metallization. Metal vias electrically couple the metal layers to one another. A dielectric thin film insulates the metal layers. The insulator exists between metallization layers, as well as surrounding the contacts and vias.
[0003] A semiconductor device is manufactured sequentially where one film is fabricated at a time. The sequence generally includes depositing a thin film material, patterning the material using photolithography and plasma etching, and then depositing another thin film material on the patterned material. There may be planarization steps in between the deposition steps, to reduce topographical effects that can limit photolithography and etching.
[0004] The metallization sequence of fabrication is usually as follows. A layer of silicon oxide is deposited on the substrate. The substrate may be the transistor elements or an underlying layer of metallization. Openings are formed in the silicon oxide. These openings are usually shaped as holes. The openings are filled with a conductor metal, usually aluminum or tungsten to form contacts or vias, as the case may be. Excess metal is removed from the surface and the surface is planarized. Then, a metallization material is deposited on the planarized silicon oxide containing contact or via plugs, usually this is aluminum. The aluminum is patterned using plasma etching to form electrically conductive lines that are coupled to the underlying metal or transistor elements through vias or contacts. Then, the patterned aluminum lines are covered with silicon oxide. Then, openings are formed in the silicon oxide, and the openings are filled with metal to create vias. The sequence is repeated until the desired number of metallization layers is attained.
[0005] In a semiconductor manufacturing method known as “damascene”, a layer of silicon oxide is deposited on a substrate surface, and openings are formed in the silicon oxide to create a trench pattern in the shape of metal lines. Then, metal is deposited into the trenches of the pattern. The metal may be planarized to remove excess from the top surface of the silicon oxide. The result is a series of metal lines surrounded by silicon oxide, but it is achieved by depositing the metal into trenches in the silicon oxide, as opposed to depositing a blanket layer of metal and patterning it to form lines.
[0006] As the trend in semiconductor fabrication moves toward using copper as the conductive metal, it is desirable to use damascene, which avoids etching metal, because of technical problems with plasma etching copper. A limitation to the damascene process, however, is that it is difficult to properly endpoint the silicon oxide etch. This is because, the silicon oxide not only serves as the filler material around the metal lines, it also serves as insulation between metallization layers. Thus, a portion of the silicon oxide resides below the level on which to place the metal lines. It is evident, then, that when the silicon oxide must be etched, endpointing is difficult because it must be etched to enough depth to expose underlying vias, but in places where there are no vias to expose, the etch simply must be stopped to a measured depth. Simply stopping an etch to a measured depth can be done at a designated point on a substrate, but difficulties arise when the etch stop must be done uniformly across the substrate.
[0007] To address the etch stop problem with damascene, it is desirable to utilize an etch stop film, so that when the etch stop film is reached, the selectivity of the etch process favoring the silicon oxide will enable etch endpointing to be done more uniformly across the substrate. The etch stop film must also have insulative properties. A proposed etch stop film is silicon nitride.
[0008] Silicon nitride and silicon oxide are both formed using chemical vapor deposition. Each is traditionally formed in separate processing chambers. A sequence for forming the films may be to insert a substrate into a silicon nitride process chamber, deposit the silicon nitride, remove the substrate, insert the substrate into a silicon oxide chamber, and form the silicon oxide. There is an obvious downside to using two separate chambers which is that, when the substrate is removed from the silicon nitride process chamber, contamination could form on the film. The contamination could inhibit the formation of chemical bonds and result in adhesion problems when the silicon oxide is formed on the silicon nitride. Another problem with using two separate processing chambers is simply added process time from maneuvering the substrate from one processing chamber to another. Another problem with using silicon nitride and silicon oxide as a stack is the abruptness of the nitrogen content and oxygen content of the films at the film interface. An abrupt interface leads to adhesion problems for the silicon oxide due to large interfacial stresses.
[0009] It would be advantageous to avoid the contamination, extra processing time, and adhesion problems when utilizing a stacked dielectric film of silicon nitride and silicon oxide as the insulator in semiconductor devices.
SUMMARY OF THE INVENTION
[0010] The invention discloses a process for forming a silicon oxide film over silicon nitride on a substrate. A substrate is placed within a plasma processing chamber, and a silicon nitride film is deposited thereon. Then, the silicon oxide film is formed within the same plasma process chamber.
[0011] In a further aspect of the invention, a novel semiconductor device is disclosed. There is a substrate, on which there is a layer of silicon nitride. There is a layer of graded silicon oxynitride on the silicon nitride. A layer of silicon oxide is on the graded silicon oxynitride.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Drawings are provided to further illustrate details of the disclosure below. The drawings do not limit the scope of the invention to the features shown. The features are not drawn to scale.
[0013] [0013]FIG. 1 is a cross-sectional view illustrating a silicon nitride film, a graded silicon oxynitride film thereon, and a silicon oxide film thereon.
[0014] [0014]FIG. 2 is a graph illustrating the silicon nitride to silicon oxide gradation.
[0015] [0015]FIG. 3 is a cross-sectional view illustrating a semiconductor device having a silicon nitride film, a graded silicon oxynitride film, and a silicon oxide film.
[0016] [0016]FIG. 4 is an illustration of a side view of the interior or a plasma processing chamber where the three films, silicon nitride, silicon oxynitride and silicon oxide, may be formed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Disclosed is a method of formation of a stacked film of silicon nitride and silicon oxide. The two films are preferably formed within the same plasma processing chamber. In another aspect, the two films contain a silicon oxynitride layer between the two films, where the oxygen percentage in the silicon oxynitride is graded to avoid an abrupt silicon nitride and silicon oxide interface. The invention will be described first in terms of the stacked film structure. Then, a method of forming the stacked film will be described. Any reference to dimensions are purely for illustrative purposes, and are determined by the design rules of a particular semiconductor device. Any reference to “approximate” or like term, should be construed as a target manufacturing specification, plus or minus variation within reasonable manufacturing tolerances, unless otherwise specified. The detailed description will refer to silicon oxide, but it should be construed very generically, so that silicon oxide includes any oxides of silicon in varying compositions, and various additives that may be used. For example, a “silicon oxide” film may actually be fluorinated silicon oxide. The context of the description will be in semiconductor processing, and more specifically, in the use of copper for metallization in a damascene process. Although the context is copper damascene process, the invention is not limited to that context in any way. Nor is the invention limited to semiconductor devices or semiconductor processing. A person of ordinary skill in the art is expected to apply the invention to various contexts as reasonably can be expected of a person of such skill; the description below should not be construed to limit the scope of the invention to the aspects described.
[0018] [0018]FIG. 1 illustrates in cross-section, a preferred embodiment of the stacked silicon nitride and silicon oxide film. There is a substrate 10 , which may be a silicon wafer or a silicon wafer with silicon oxide deposited on top of the wafer. A silicon nitride film 20 is formed on substrate 10 . Silicon nitride film 20 may be approximately 100 angstroms to 2000 angstroms in thickness. A silicon oxide film 30 is held a distance above silicon nitride film 20 . Silicon oxide film 30 may be approximately 5000 angstroms to 3 microns in thickness. A layer of graded silicon oxynitride 40 separates silicon nitride film 20 from silicon oxide film 30 . Silicon oxynitride 40 may be approximately 300 to 2000 angstroms thick. The percentage of oxygen is graded in silicon oxynitride 40 so that the bottom of silicon oxynitride 40 at the silicon nitride interface 50 contains approximately zero percentage of oxygen. The top of silicon oxynitride 40 at the silicon oxide interface 60 contains an oxygen composition that is approximately 50 to 70% oxygen, preferably approximately 60% oxygen. The minimum thickness of silicon oxynitride 40 is determined by the desired oxygen and nitrogen concentration gradients. The amount of oxygen in silicon oxynitride 40 can be measured in estimate using depth profile SIMS or similar technique. Because in semiconductor manufacturing it is advantageous to minimize processing time, the maximum thickness of silicon oxynitride 40 is preferably determined by the minimum thickness required for the desired concentration profiles plus added thickness for manufacturing tolerances including film thickness uniformity across substrate 10 .
[0019] [0019]FIG. 2 shows a graphical description of the gradation of oxygen in silicon oxynitride 40 of FIG. 1. At approximately zero film thickness, the oxygen percentage is about zero. At approximately 500 to 1000 angstroms distance from silicon nitride, the oxygen percentage is about 60%. Note that varying the process for forming silicon oxynitride 40 can vary the composition of oxygen with respect to film thickness. A description of a process is provided further below.
[0020] [0020]FIG. 3 shows in cross section an application of the present invention to a copper metallization semiconductor device. There is a semiconductor wafer substrate 100 . Transistor structures 110 are built on substrate 100 . A first dielectric layer 120 is disposed above transistor structures 110 . First dielectric layer 120 may be silicon oxide, at a thickness of approximately 1 to 2 microns. First dielectric layer 120 may be deposited over transistor structures using a chemical vapor deposition, to create a blanket layer of first dielectric 120 . Contact holes 140 within first dielectric 120 are filled with a metal such as tungsten, aluminum or copper, to enable electrical interconnection between transistor structures 110 and electrical wiring above the device. Contact holes 140 may be created in first dielectric layer 120 by plasma etching a hole pattern into first dielectric layer 120 , and filling the pattern with the desired metal using vapor deposition techniques.
[0021] Directly above first dielectric layer 120 containing filled contact holes 140 , there is a second dielectric layer 125 . Second dielectric layer 125 surrounds a first metallization 145 . Second dielectric layer 125 may be a fluorinated silicon oxide, so that the dielectric constant of the film is lower than that of pure silicon dioxide. First metallization 145 may be made of copper, and is patterned in a series of lines for forming a first wiring plane in the semiconductor device. First metallization 145 is formed by opening a pattern in second dielectric layer 125 by plasma etching, and then filling the openings in the pattern with copper or other preferred metal, and then planarizing the surface to remove any excess metal. This “single damascene” technique effectively fills contact holes 140 with the desired metal. First metallization 145 and second dielectric 125 may be approximately 5000 angstroms to 1 micron in thickness.
[0022] The next series of films is a silicon nitride/silicon oxynitride/silicon oxide stack. There is a first silicon nitride etch stop 150 that is directly above the surface of second dielectric 125 and first metallization 145 . Directly above the surface of first silicon nitride 150 is a first graded silicon oxynitride 160 . Directly above the surface of first graded silicon oxynitride 160 is a third dielectric layer 170 , which may be a fluorinated silicon oxide (“SiOF”) so that the dielectric constant of third dielectric layer 170 is lower than that of pure silicon dioxide. First silicon nitride 150 is formed directly over second dielectric 125 and first metallization 145 preferably by vapor deposition, to a thickness of approximately 40 nanometers to 500 nanometers, or 400 angstroms to 5000 angstroms. It is important to make first silicon nitride 150 as thin as possible within manufacturing feasibility to avoid dielectric constant increase effects. First graded silicon oxynitride 160 is preferably formed using vapor deposition, within the same processing chamber used for forming first silicon nitride 150 , by combining the process gases used for forming first silicon nitride 150 and SiOF 170 . First graded silicon oxynitride 160 is preferably a thickness of approximately 300 to 2000 angstroms. SiOF 170 is preferably formed using vapor deposition, within the same processing chamber used for forming first silicon nitride 150 and graded silicon oxynitride 160 , to a thickness of approximately 5000 angstroms to 3 microns.
[0023] Within the plane of SiOF 170 there is a dual structure of a first via 155 and a second metallization 165 . First via 155 is formed by etching a hole within SiOF 170 , and, after forming a larger opening within SiOF 170 to create the second metallization 165 , extending the hole through the thickness of SiOF 170 , first graded silicon oxynitride 160 and first silicon nitride 150 so that the hole extends to first metallization 145 . First via 155 is in direct metal-to-metal contact with first metallization 145 . Second metallization 165 is formed by etching line patterns into SiOF 170 , preferably in-situ with cutting the hole for first via 155 as explained above. The line patterns for second metallization 165 are aligned with the hole patterns for first via 155 to enable direct metal-to-metal contact between first via 155 and second metallization 165 . After creating the hole openings and line openings within the stack of SiOF 170 , first silicon oxynitride 160 and first silicon nitride 150 , first via 155 and second metallization 165 are completed by filling the openings with copper or other desired electrically conductive material, utilizing a vapor deposition process.
[0024] The next structure layer of the semiconductor device may be similar to the above. There is a second silicon nitride 180 , formed directly above the surface of SiOF 170 and second metallization 165 . Directly above the surface of second silicon nitride 180 is a second graded silicon oxynitride 190 . Directly above the surface of second graded silicon oxynitride 190 is a fourth dielectric layer 200 , also referred to as second SiOF 200 , so that the dielectric constant of second SiOF 200 is lower than that of pure silicon dioxide. Second silicon nitride 180 is formed preferably by vapor deposition, to a thickness of approximately 40 nanometers to 500 nanometers, or 400 angstroms to 5000 angstroms. It is important to make second silicon nitride 180 as thin as possible within manufacturing feasibility to avoid dielectric constant increase effects. Second graded silicon oxynitride 190 is preferably formed using vapor deposition, within the same processing chamber used for forming second silicon nitride 180 , by combining the process gases used for forming second silicon nitride 180 and second SiOF 200 . Second graded silicon oxynitride 190 is preferably a thickness of approximately 300 to 2000 angstroms. Second SiOF 200 is preferably formed using vapor deposition, within the same processing chamber used for forming second silicon nitride 180 and second graded silicon oxynitride 190 , to a thickness of approximately 5000 angstroms to 3 microns.
[0025] Within the plane of second SiOF 200 there is a dual structure of a second via 175 and a third metallization 185 . Second via 175 is formed by etching a hole within second SiOF 200 , and, after forming a larger opening within second SiOF 200 to create the third metallization 185 , extending the hole through the thickness of second SiOF 200 , second graded silicon oxynitride 190 and second silicon nitride 180 so that the hole extends to second metallization 165 . Second via 175 is in direct metal-to-metal contact with second metallization 165 . Third metallization 185 is formed as explained above, by etching line patterns into second SiOF 200 , preferably in-situ with cutting the hole for second via 175 . The line patterns for third metallization 185 are aligned with the hole patterns for second via 175 to enable direct metal-to-metal contact between second via 175 and third metallization 185 . After creating the hole openings and line openings within the stack of second silicon nitride 180 , second silicon oxynitride 190 and second SiOF 200 , second via 175 and third metallization 185 are completed by filling the openings with copper or other desired electrically conductive material, utilizing a vapor deposition process.
[0026] The process for forming the stacked silicon nitride and silicon oxide film can be carried out in a commercial chemical vapor deposition chamber. An example process is described in reference to FIG. 4. Substrate 300 is placed within a plasma processing chamber 310 . The preferred plasma processing chamber utilizes microwave frequency source 320 for forming plasma in an electron cyclotron resonance. Other sources of plasma such as inductive coupling can be used. The processing chamber 210 is pumped down to a minimum pressure for processing chamber 310 .
[0027] Then, silicon nitride-forming gases are introduced, preferably these are silane (SiH 4 ) 330 and nitrogen (N 2 ) gas 340 . The gases flow through an inlet 350 (ammonia may be used if the system is not a high density plasma system capable of dissociating diatomic nitrogen). The gas flow rates depend on the size of the processing chamber 310 and the size of the substrate 300 ; an example of a total gas flow rate may be approximately 80 standard cubic centimeters per minute (sccm) to 200 sccm. A ratio of approximately ¼ to ½ of SiH 4 to N 2 may be used. The temperature of substrate 300 is regulated at approximately 375 to 450 degrees celsius. The substrate temperature is regulated by securing the substrate 300 against a helium-cooled chuck 360 preferably by electrostatic force or a mechanical clamp. The plasma is formed by applying a microwave frequency to the process gases, at a power level of approximately 450 to 750 watts. Substrate 300 may be biased using radio frequency at about 3000 watts. The various process parameters may be adjusted to achieve a desired refractive index and deposition rate for the silicon nitride. Silicon nitride is formed to a desired thickness.
[0028] Next, a graded silicon oxynitride is formed. Without modifying the electrical or thermal parameters described above, the flowrate of the gases used for forming silicon nitride is reduced by approximately one half, and gases for forming SiOF (since it can be desirable to use SiOF in lieu of pure silicon dioxide) are added to the mixture, for an example total gas flow rate of approximately 130 to 250 sccm. Such gases for forming SiOF may be silicon tetrafluoride (SF 4 ) 370 and oxygen (O 2 ) 380 . SiF 4 370 may be approximately 10 to 20% of the total gas flow, and O 2 380 may be approximately 50 to 75% of the total gas flow, and the ratio of SiH 4 330 to N 2 340 remain approximately the same as for depositing silicon nitride. Silicon oxynitride is formed to a desired thickness.
[0029] Next, without removing substrate 300 from processing chamber 310 , the SiOF is formed. The flow rates of SiF 4 370 and O 2 380 from the previous step are approximately doubled, and SiH 4 330 is preferably turned off. N 2 340 may remain on but preferably at a flowrate reduced by 75 to 50% from the previous step, for an example total gas flow rate of approximately 200 to 300 sccm. Power levels for substrate bias and microwave power may be adjusted to obtain the desired refractive index and deposition rate for silicon oxide. When the desired amount of silicon oxide is formed, the plasma is turned off, and substrate 330 is removed from process chamber 310 .
[0030] A process has been described for forming a silicon nitride, silicon oxynitride and SiOF films all within the same plasma processing chamber. Forming a stacked silicon nitride and silicon oxide film structure in the same chamber has the advantage of avoiding contamination to the silicon nitride surface that may result if the substrate is removed from the processing chamber and inserted into a separate chamber for forming the silicon oxide. Additionally, a graded silicon oxynitride can be formed by having a step in between the formation of silicon nitride and silicon oxide, where the gases for forming the two films are merged together. A graded silicon oxynitride is advantageous in that it helps the silicon oxide adhere to the silicon nitride by having a gradual, rather than abrupt, interface. While details have been provided on the process for formation of a silicon nitride, silicon oxynitride and silicon oxide stacked film, they are provided for an example in a semiconductor fabrication context only. Gas chemistries, power levels, bias, pressure, and temperature may differ depending on the processing chamber used, the type of plasma that is formed, the size or type of substrate, and the desired refractive indices and deposition rates. Other details that may have not been provided may be obtained by experimentation by a person of ordinary skill in the art. While particulars of the structure and process have been provided here, such details should not be construed to limit the present invention in any way, as the invention is limited only by the claims below. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a control system for an automotive vehicle for controlling vehicular driving behavior. More specifically, the invention relates to a vehicle driving control system which tactically combining non-human control which is performed purely depending upon vehicular driving parameters reflecting vehicular driving condition and/or vehicular environmental condition and human control which is performed with taking driver's driving characteristics, feeling, tendency and so forth into account.
2. Description of the Background Art
In the modern automotive technologies, various vehicular driving control systems have been proposed and developed in order to optimize vehicular driving performance and behavior. Many of such control systems monitors vehicular driving condition and vehicular driving environmental condition for depending thereupon. Such type of control derives control signals purely depending upon the monitored vehicle driving condition and environmental condition and according to preprogrammed and rigidly set control schedule irrespective of the driver's driving characteristics, feeling, tendency and other human feeling factor. Therefore, such type of control will be referred to as "non-human control". On the other hand, according to progress of computer technologies, there have been developed fuzzy computer, neuron computer, artificial intelligence (AI) computer and so forth. Such advanced computer technologies enables to automotive control systems to perform control operations not only depending upon vehicle driving condition and vehicular environmental condition but also depending upon driver's driving characteristics, tendency, feeling and so forth. Such type of control will be hereafter referred to as "human control".
For example, Japanese Patent First (unexamined) Publication (Tokkai) Heisei 1-167434 discloses a throttle control system for an automotive internal combustion engine, in which a throttle valve angular position is controlled in response to depression of an accelerator pedal. The disclosed control system recognizes vehicular driving environmental condition, such as hill climbing, heavy traffic road and so forth, and selects one of a plurality of control characteristics maps depending upon the vehicular driving environmental condition. Map look-up is performed against the selected one of map in terms of the operational magnitude of the accelerator pedal. The shown system further predict the driver's will of vehicular behavior, acceleration and deceleration characteristics, e.g. swift acceleration, moderate acceleration, according to driver's accelerator control behavior.
Though such advanced vehicle control systems have obtained certain gain to make the vehicular driving behavior closer to the ideal or optimum behavior. However, on the other hand, the control systems proposed in the prior art have not been completely satisfactory. Particularly, since the prior proposed system have non-human control and human control mixingly. It required another logic for governing interrelation between the non-human control and the human control. The conventional control system requires substantial cost in development of control programs. Further to say, the conventionally developed control systems have been generally based on the traditional non-human control logic and taken the human factor as correction parameters for make the control characteristics close to the driver's feeling. For accomplishing this, logic of control had to be established with taking all parameters both for non-human control and human control. In order to establish correction pattern for human control, lots of experiments has to be made and the result of such experiments had to be reflected. Therefore, despite of the extensive effort in establishing the correction pattern, the established correction pattern cannot be satisfactorily adapted for all driver's driving characteristics.
Furthermore, in the prior proposed systems, there is a tendency to arise inconsistency between non-human control and human control. In order to manage such inconsistency and govern control system, another logic for selecting one of non-human or human control becomes necessary. This clearly increases cost for designing and developing the control system.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide a novel control system for an automotive vehicle which can satisfactorily establish harmonization of non-human control and human control with lesser effort in designing the system.
In order to accomplish aforementioned and other objects, a control system for controlling automotive vehicle driving behavior, according to the present invention, has a parameter monitoring means for monitoring vehicular driving parameters, a vehicular driving environmental condition predicting means which predicts vehicular driving environmental condition based on generalized intelligence base which is common to all vehicles, a control output generating means for deriving a control output on the basis of the predicted vehicular driving environmental condition, a personal driving characteristics detecting means for detecting unique characteristics of each individual driver, a control output recollecting means which learns relationship between said vehicular driving parameters and the personal driving characteristics for recollecting control output on the basis of said vehicular driving parameters, and a control output selecting means which selects one of control outputs from said control generating means and said control output recollecting means in such that when recollected control output present, the recollected control output is selected and, otherwise the control output derived by the control output generating means is selected.
According to one aspect of the invention, a control system for an automotive vehicle for controlling vehicular component, comprises:
first means for monitoring preselected control parameters for producing a control parameter indicative signals;
second means for deriving a first control signal on the basis of the parameter indicative signals according to a preset common control schedule which defines operating modes of the vehicular component in relation to operating condition represented by the control parameter;
third means for accepting manual entry of command for selecting operational mode of the vehicular component and learning operating conditions at entry of the manually entered command as a personal unique data reflecting driver's preference;
fourth means for detecting the control parameter indicative signals representing operational condition coincidence with learnt condition for recollecting manually commanded operational mode and for producing a second control signal; and
fifth means for selectively supplying one of the first and second control signals to the vehicular component for controlling operation thereof, the control signal supplying means outputting the first control signal while absence of the second control signal and outputs the second control signal while the second control signal present.
The third means may include neural network for learning operational condition of the vehicular component at the occurrence of manually entered command for updating neural network storage.
According to another aspect of the invention, a control system for an automotive vehicle for controlling vehicular component, comprises:
first means for monitoring preselected vehicle driving parameters for producing a vehicle driving parameter indicative signals;
second means for deriving a first control signal on the basis of the parameter indicative signals according to a preset common control schedule which defines operating modes of the vehicular component in relation to vehicular driving condition represented by the control parameter;
third means for accepting manual entry of command for selecting operational mode of the vehicular component and learning vehicular driving conditions at entry of the manually entered command as a personal unique data reflecting driver's preference;
fourth means for detecting the control parameter indicative signals representing vehicular driving condition coincidence with learnt condition for recollecting manually commanded operational mode and for producing a second control signal; and
fifth means for selectively supplying one of the first and second control signals to the vehicular component for controlling operation thereof, the control signal supplying means outputting the first control signal while absence of the second control signal and outputs the second control signal while the second control signal present.
The third means may include neural network for learning vehicular driving condition at the occurrence of manually entered command for updating neural network storage. Preferably, the fourth means is responsive to the vehicle driving parameter indicative signal for predicting a vehicle driving condition and recollects one of manually entered command when the predicted vehicle driving condition coincidence with the corresponding learnt driving condition for deriving the second control signal based on the recollected command.
According to a further aspect of the invention, a shift control system for an automotive automatic power transmission comprises:
an automatic power transmission unit having electrically operably shift control means for selectingly establishing one of a plurality of transmission speed ratio;
a sensor means for monitoring vehicle driving parameter associated with transmission speed ratio selection for producing a vehicle driving condition indicative parameter signal;
a shift pattern storage means storing a plurality of preset shift patterns which are set in terms of the vehicle driving parameter;
a manual selector means for manual entry of a pattern selector command for manually selecting one of a plurality of shift patterns in the shift pattern storage means;
a neural network responsive to the manually entered pattern selector command for learning condition of the vehicle driving conditions based on the vehicle driving condition indicative parameter signal and updating storage therein;
a controller means for detecting vehicle driving condition based on the vehicle driving condition indicative parameter signal, comparing the detected vehicle driving condition with learnt vehicle driving conditions, recollecting one of commands stored in the neural network when the detected vehicle driving condition coincidence with the learnt vehicle driving condition, and otherwise selecting one of a plurality of shift pattern according to a predetermined shift pattern selecting schedule, and performing shift control by controlling operation of the shift control means according to the selected shift pattern.
The controller means may predict vehicle driving condition including vehicle driving environmental condition based on the vehicle driving condition indicative parameter signal and performs recollection of one of the stored commands and selection of shift pattern based on the predicted vehicle driving condition. In such case, the controller means may generate a first control signal based on the shift pattern selected according to the predetermined shift pattern selecting schedule and a second control signal based on the shift pattern corresponding to the recollected command, and selects the second control signal whenever the recollected command is present and otherwise selects the first control signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood more fully from the detailed description given herebelow and from the accompanying drawings of the preferred embodiment of the invention, which, however, should not be taken to limit the invention to the specific embodiment but are for explanation and understanding only.
In the drawings:
FIG. 1 is a schematic block diagram of the preferred embodiment of a control system, according to the invention, in which the idea of the present invention is applied for shift control for an electronically controlled automatic power transmission; and
FIG. 2 is a flowchart showing a routine for selecting shifting pattern to be used in shift control to be implemented by the shift control system of FIG. 1;
FIG. 3 is a flowchart showing a routine for performing shift control based on the selected shift pattern; and
FIG. 4 is a chart showing example of shifting pattern to be selected in execution of the routine of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, the preferred embodiment of a control system according to the present invention, will be discussed herebelow in terms of shift control of an automatic power transmission of an automotive vehicle. However, as can be understood, the control system according to the present invention is applicable not only to automatic power transmission shift control, but also to controls for an automotive internal combustion engine, a suspension system, a brake system, a steering system and so forth. Further to say, the idea of the present invention may also applicable for automatic air conditioner control, audio control and so forth. Therefore, the preferred embodiment of the control system which hereinafter discussed, should be understood as one of a plurality of applications of the inventive idea of the invention.
Referring now to FIG.1, the preferred embodiment of the control system is applied to an automotive vehicle which has an electronically controlled fuel injection internal combustion engine 1, an automatic power transmission 2 incorporating a torque converter 10. The automatic power transmission 2 forms a power train together with a differential gear unit 3 for adjusting driving torque to be distributed to driving wheels 4.
As is well known, the electronically controlled fuel injection internal combustion engine 1 is controlled a fuel injection amount and spark ignition timing by means of an engine control unit 5 which comprises a microcomputer. In order to provide engine control parameters, various engine driving parameter sensors, such as an intake air flow sensor 9, a throttle angle sensor 8, a vehicle speed sensor 7, an engine speed sensor 6 and so forth are connected to the engine control unit 5. Though FIG. 1 explanatorily illustrates only elemental engine driving parameter sensors listed above, additional sensors can be provided for supplying additional engine control parameters in order to adapt the engine control characteristics to the driving conditions. As is well known, the intake air flow sensor may comprise a flap type air flow meter, hot wire air flow meter, Karman's vortex type air flow meter and so forth for monitoring air flow rate through an induction passage of the engine 1 and produce an intake air flow rate indicative signal Q. This air flow sensor 9 thus provides an engine load condition indicative parameter. In this sense, the air flow meter can be substituted with an intake vacuum sensor. The throttle angle sensor 8 is associated with a throttle valve in the induction system for monitoring an angular position of the throttle valve to produce a throttle angle indicative signal TH. The vehicle speed sensor 7 is designed for monitoring a vehicular travailing speed to produce a vehicle speed indicative signal V. The engine speed sensor 6 may comprises a crank angle sensor which monitors crankshaft angular position to produce a crank reference signal at every predetermined angular position of the crankshaft and a crank position signal at every predetermined angle of angular displacement of the crankshaft. The engine speed is derived on the basis of one of the crank reference signal and crank position signal. The engine speed sensor 6 thus provide an engine speed indicative signal N E .
The engine control unit 5 processes the input engine driving parameters from the sensors to derive a fuel injection amount, spark ignition timing and so forth. As is well known, a basic fuel injection pulse width T p is derived based on the engine load Q and the engine speed N E . The basic fuel injection pulse width T p may be corrected based on various correction coefficients. On the other hand, basic spark advance is derived on the basis of the T p value and the engine load Q and corrected with various known correction factors. The engine control unit 5 thus outputs a fuel injection control signal and a spark ignition control signal at predetermined timings which is determined in relation to the engine revolution cycle.
The torque converter 10 is associated with the output shaft of the engine 1 to be driven by the engine output torque. The torque converter 10 is connected to an input shaft 12 of a transmission gear assembly 11 which includes a plurality of friction elements, e.g. clutches and brakes, to selectively establish various transmission speed ratio. The transmission gear assembly 11 is connected to the differential gear unit 18 via an output shaft 13.
In order to control engagement and disengagement of the friction elements in the transmission gear assembly 11, a control valve unit 15 is provided. The control valve unit 15 includes a line pressure controlling duty solenoid 16, a shift control solenoids 15a and 15b. The control valve unit 15 modulates line pressure P L to be supplied for respective friction elements and controls distribution of the line pressure for selectively supplying the line pressure to respective friction elements in order to selectively establish and release engagement to establish desired one of the transmission gear ratio. The operation of the control valve unit 15 is controlled by control signals supplied from a transmission control unit 14 which also comprises a microcomputer.
In general, the transmission control unit 14 controls energization and deenergization of the solenoids 15a and 15b for establishing and releasing engagement of the friction elements in the transmission gear assembly 11 with combination of the energized and deenergized solenoids, which combination of the energized and deenergized solenoids defines mutually distinct working fluid path for supplying line pressures. Also, the transmission control unit 14 controls energization and deenergization of the duty solenoid 16 with a given duty cycle in order to modulate predetermined magnitude of line pressure P L .
In order to perform control for operation of the transmission, the transmission control unit 14 is connected to the throttle angle sensor 8, the vehicle speed sensor 7, the engine speed sensor 6 to receive therefrom the throttle angle indicative signal TH, the vehicle speed indicative signal V and the engine speed indicative signal N E . In addition, the transmission control unit 14 is connected to an input speed sensor 17 which is associated with the input shaft 12 to monitor the rotation speed at the input shaft, and an output speed sensor 18 associated with the output shaft 13 to monitor the rotation speed of the output shaft. The input speed sensor 17 produces an input speed indicative signal N T based on the monitored input speed. On the other hand, the output speed sensor 18 produces an output speed indicative signal N 0 representive of the monitored rotation speed at the output shaft 13. Furthermore, the transmission control unit 14 is connected to a brake switch 19 which is detective of application of brake and produces a braking condition indicative signal when depression of a brake pedal is detected. The transmission control unit 14 is further connected to an economy mode selector switch 20 which is manually operable for selecting transmission shifting pattern set for better fuel economy. Though there has not been illustrated, it may also possible to connect another manually operable mode selector switch for selecting a power mode for selecting powerful shift pattern for better vehicular acceleration characteristics.
Based on the foregoing input parameters, the transmission control unit 14 performs transmission shift control operation. The operation to be performed by the transmission control unit 14 will be discussed herebelow with reference to FIGS. 2 and 3. The flowcharts of FIGS. 2 and 3 show respective routines for selecting transmission shift pattern and performing shift control. These routine are executed as time-triggered interrupt routines to be triggered every predetermined intervals.
In the process of FIG. 3, the input parameters, i.e. the throttle angle signal TH from the throttle angle sensor 8, the vehicle speed indicative signal V from the vehicle speed sensor 7, the engine speed indicative signal N E from the engine speed sensor 6, the input speed indicative signal N T from the input speed sensor 17, the output speed indicative signal N 0 from the output speed sensor 18, the braking condition indicative signal from the brake switch 19 and the economy mode selection signal from the economy mode switch 20 are read out, at a step 31. Then, at a step 32, a vehicle driving condition is discriminated whether the vehicle is traveling on a highway or not. As can be appreciated, at the highway, the vehicular traveling speed can be relatively high and maintained relatively constant and occurrence of application of brake is less frequent than that in the town road. Therefore, discrimination of highway can be made by checking the vehicle speed and frequency of application of brake. At the step 32, an average vehicle speed is derived and checked whether the average is speed is high or low. Also, distribution of instantaneous vehicle speed is also checked whether the vehicle speed fluctuation is relatively large or small. In addition, application frequency of the brake is checked. When the average speed is relatively high, the vehicle speed fluctuation is relatively in narrow range and frequency of application of brake is small, judgement can be made that the vehicle is traveling on the highway. If judgement can be made that the vehicle is traveling through the highway at the step 32, learnt data stored in terms of the same or similar combination of parameters at a step 33. In the shown embodiment, check is performed whether the manual input through the economy mode switch 20 is entered at the same or similar vehicle driving condition represented by the combination of the vehicle driving parameters. If the learnt date as checked cannot be found, process goes to the step 34 in which a 3-4shift line for highway mode as illustrated by broken line in FIG. 4 is selected at a step 34. Then, check is performed whether a predetermined period is expired after performing 4-3 down-shifting, at a step 35. The predetermined period is set at several seconds. Checking of elapsed time after 4-3 down-shifting is maintained over the predetermined period, e.g. several seconds. After expiration of the predetermined period as checked at the step 35, check is performed whether input for economy mode shift pattern is entered through the economy mode switch 20 at a step 36. In economy mode ordering input is not entered as checked at the step 36, process goes END and returned to a background job which governs a pluarlity of control routines. Therefore, when the answer is maintained at that adapted for highway as set at the step 34.
On the other hand, if order for economy mode is detected as checked at the step 36, learnt data for not to shift the 3-4 shifting pattern to the highway mode pattern is written in in a neural network so as to prevent the shift pattern from being shifted to the highway mode shift pattern. Updation of the learnt data is performed by way of back propagation and so forth. Thereafter, 3-4 shift pattern is returned to a predetermined low vehicle speed shift pattern as shown by solid line in FIG. 4, at a step 38.
On the other hand, of judgement at the step 32 is that the vehicle traveling not in the highway, 3-4 shift pattern is returned to an economy mode shift pattern as shown by solid line in FIG. 4, at a step 39. On the other hand, when the previously stored combination of the parameters for ordering economy mode shift pattern is detected as checked at a step 33, then recollection of the 3-4 shift pattern is performed at a step 40. The based on the recollected 3-4 shift pattern at the step 40, the 3-4shift line is shifted toward the lower speed mode.
It should be appreciated that though the shown routine in FIG. 2 switches the shifting pattern between the highway mode pattern and economy mode shift pattern, it may be possible to vary the shifting pattern continuously between the highway mode pattern and economy mode shift pattern.
FIG. 3 shows shift control routine for controlling the transmission speed ratio according to the shift pattern selected through the routine of FIG. 2. At the initial stage of execution of the shown routine, the transmission speed ratio adapted to the instantaneous vehicle driving condition is derived at a step 51. In practice, derivation of the adapted transmission speed ratio is determined in terms of the vehicle speed V and the throttle valve angular position TH. Then, the transmission speed ratio derived at the step 51 is compared with the instantaneous transmission speed ratio at a step 52 in the order to make judgement whether shifting operation is required or not. In the derived transmission speed ratio coincident with the instantaneous transmission speed ratio, process directly goes END and return to the main routine. Therefore, the instantaneous transmission speed ratio is maintained. On the other than, when derived transmission speed ratio is different from that of the instantaneous transmission speed ratio, judgement can be made that shifting operation is required. When judgement that shifting operation is required is made at a step 52, control signals are supplied to the shift solenoids 15a and 15b to establish combination of the energized solenoid and deenergized solenoid corresponding the derived transmission speed ratio.
As can be seen herefrom, according to the shown embodiment, once the driver's preference of economy mode shift pattern even at the highway, switching of transmission shift pattern to the highway mode is prevented. On the other hand, when the driver commands the economy mode shift pattern, the driver's preference at the specific condition is learnt and stored in the neural network. Therefore, during normal driving operation, neural network can be updated. With such design of control routines, it is initially required to set a plurality of shift patterns to be selected according to the vehicle driving condition as well as the examiner's preference. This can substantially reduces work load for designing the control system.
While the present invention has been discussed in terms of the preferred embodiment of the invention, the invention should be appreciated that the shown control system is applicable not only for transmission shift control, power steering control, suspension control, engine control and so forth. Therefore, the invention should be appreciated to include all application and all process which can be implemented without departing from the principle of the invention which is set out in the appended claims.
For example, in case of the suspension control, suspension characteristics may be controlled both in human and non-human controls. For example, in order to perform suspension control, traveling resistance, steering pattern and so forth are analyzed for adapting the suspension characteristics for the vehicle driving condition. In case of the mountainous road, it is generally required harder suspension characteristics for vehicular driving stability. However, some of the drivers may prefer maintenance of softer suspension characteristics. In such case, the driver may manually selects the softer suspension mode. The shown system may then learn the driver's preference and prevent the suspension characteristics from being switching into harder suspension mode when similar driving condition is detected. | 4y
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RELATED APPLICATION DATA
[0001] This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/092,877, filed Aug. 29, 2008, the entire contents of which are incorporated herein by reference.
FIELD
[0002] The present disclosure relates to a material removal tool, such as a line bar tool, with cartridges pivotably housing a pair of cutting inserts, which pivot to a cutting position under a biasing force applied to the cartridge, for example by forces applied directly or indirectly by an actuation fluid.
BACKGROUND
[0003] In the discussion of the background that follows, reference is made to certain structures and/or methods. However, the following references should not be construed as an admission that these structures and/or methods constitute prior art. Applicant expressly reserves the right to demonstrate that such structures and/or methods do not qualify as prior art.
[0004] Conventional flexing cartridges housing cutting inserts are used to adjust (extend and retract) the radial positions of cutting inserts on material removal tools. These cartridges are typically anchored at one end of an elongate body to allow flexing at a non-anchored end. A cutting insert is mounted to the non-anchored end and thus could be repositioned radially by biasing the cartridge to flex/unflex. The anchor position and the length of the cartridge contribute to the amount of flexing and the radial displacement of the cutting inserts. To achieve larger radial displacement, greater flexing is generally used.
SUMMARY
[0005] An exemplary material removal tool comprises a housing body including a mounting portion and an active portion, a plurality of cartridges mounted on the active portion of the material removal tool, and a plurality of seating members mounted in each of the plurality of cartridges to pivot about an axis between a retracted position and an extended position, the plurality of seating members including a pocket with a seating surface for a cutting insert.
[0006] An exemplary method for removing material from a workpiece with a rotating material removal tool comprises inserting an active portion of the material removal tool into a bore of the workpiece, positioning a surface of the workpiece to be machined radially proximate a pivot axis of a plurality of seating members mounted in a cartridge mounted on the active portion of the material removal tool, actuating the plurality of seating members to pivot the plurality of seating members to an extended position, translating the rotating material removal tool in a first axial direction to contact the surface with a first cutting insert mounted in a pocket of a first of the plurality of seating members, and translating the rotating material removal tool in a second axial direction to contact the surface with a second cutting insert mounted in a pocket of a second of the plurality of seating members.
[0007] The disclosed material removal tool can increase the density of cutting inserts (number of cutting inserts per cartridge or number of cutting inserts per axial length of tool) and therefore can cut multiple bores simultaneously by utilizing multiple inserts per a bore.
[0008] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWING
[0009] The following detailed description can be read in connection with the accompanying drawings in which like numerals designate like elements and in which:
[0010] FIG. 1 is a schematic drawing of an exemplary embodiment of a material removal tool.
[0011] FIG. 2 is a schematic drawing of the exemplary embodiment of a material removal tool of FIG. 1 showing the arrangement of some of the internal components.
[0012] FIG. 3 is a magnified view of the arrangement of some of the internal components.
[0013] FIG. 4 is a top, plan view of a cartridge with pivotable seating members.
[0014] FIG. 5 is a disassembled, perspective view of a cartridge with pivotable seating members.
[0015] FIGS. 6A and 6B are side plan views of a cartridge with pivotable seating members showing the seating members (and associated cutting inserts) in a retracted position ( FIG. 6A ) and in an extended position ( FIG. 6B ).
[0016] FIGS. 7A to 7C illustrate different operating positions for the pivotable seating members (and associated cutting inserts) while machining a workpiece.
[0017] FIG. 8 is a schematic drawing of an exemplary embodiment of a material removal tool with an alternative exemplary embodiment of a cartridge with a single pivotable seating member.
DETAILED DESCRIPTION
[0018] FIG. 1 is a schematic drawing of an exemplary embodiment of a material removal tool 10 . The material removal tool 10 comprises a housing body 12 and includes a plurality of cartridges 14 located in enclosed pockets 16 along the axial length. In a preferred embodiment, the cartridges 14 at substantially the same axial position are radially opposing each other, an arrangement that helps to balance cutting forces in the material removal tool during operation. The plurality of cartridges 14 includes a plurality of pivotable seating members 18 . The pivotable seating members 18 include a pocket 20 with a seating surface 22 for a cutting insert 24 . Suitable cutting inserts can be of any type, e.g., milling, turning, boring. One exemplary embodiment of suitable cutting inserts is the side locking insert disclosed in U.S. Application Publication No. 200710245535, the entire contents of which are incorporated herein by reference. The cutting inserts 24 mounted in the pocket 20 of each of the plurality of seating members 18 in any one cartridge can be the same type or can be of at least two different types. Further, the cutting inserts 24 mounted in the pocket 20 of each of the plurality of seating members 18 in any one cartridge can perform different cutting operations, i.e., semi-finish and finish cutting operations.
[0019] Other features of the material removal tool 10 visible in FIG. 1 include a delimiting structure, such as an adjustment assembly 26 , at a first end 28 and a connector 30 at a second end 32 . When mounted on a machine tool, the first end 28 is a distal end relative to the machine tool and the second end 32 is a mating end for attachment to the machine tool. A slot 34 in the housing body 12 is positioned near the first end 28 . The slot 34 mates with a rotary bushing (not shown) for support. During operation, the bushing rotates in conjunction with material removal tool 10 and there is no relative motion between the material removal tool 10 and the bushing. Other features include various openings, connectors and manipulators for assembly and operation of the material removal tool 10 .
[0020] The connector 30 at the second end 32 of the material removal tool 10 attaches to a machine tool, such as a HMS VF6 milling machine, for operation. The connector 30 can take any suitable form that allows attachment to a desired machine tool, e.g., attachment to a spindle of the machine tool. In an exemplary embodiment, the connector 30 has a tapered surface 36 , for example, tapered rearward or toward the second end 32 . A transition piece 38 can optionally be included with the connector 30 . An example of a transition piece 38 includes at least one feature for mating to an operating machine or to a storage system. For example, the transition piece 38 can include a circumferential groove 40 . The circumferential groove 40 , or similar structure, can provide an attachment point for mating the material removal tool 10 to a carousel storage system used in machining operations to store multiple material removal tools. In another example, the transition piece 38 can include a key slot 42 . The key slot 42 , or similar structure, can provide an orientation or a mating with a corresponding feature on the machine tool when the material removal tool is mounted for use.
[0021] The material removal tool can be generally described as having an active portion and a mounting portion. Referring again to the exemplary embodiment of FIG. 1 , the active portion I is separated from the mounting portion II at a transition line 44 . The transition line 44 can be coincident with the transition piece 38 or, as shown, can be at a different location of the material removal tool 10 . The plurality of cartridges 14 are mounted on the active portion I of the material removal tool. During operation, the active portion I is placed near or, for example during boring, inserted into the volume of the workpiece. The mounting portion II generally does not get operatively positioned within the volume of the workpiece. Thus, only locations and features on the active portion I are available for material removal operations.
[0022] In the exemplary embodiment of FIG. 1 , the active portion I has a generally regular shape, e.g., cylindrical, and has a different diameter than that of the mounting portion II. For an active portion I that has a regular shape, such as a cylinder, the diameter at any point of the active portion I is substantially constant along its axial length and an active volume of the material removal tool 10 can be defined as the volume occupied by the rotating material removal tool based on that diameter of the active portion I. For irregularly shaped active portions, an active volume can be defined as the volume occupied by the rotating material removal tool based on the largest diameter at any point of the active portion. When the active portion of the material removal tool has cutting inserts and is the radially outermost surface along the active portion, then the diameter at the outermost surface of the cutting inserts is used to determine the active volume.
[0023] FIG. 2 is a schematic drawing of the exemplary embodiment of a material removal tool of FIG. 1 showing the arrangement of some of the internal components. In FIG. 2 , the exterior of the material removal tool 10 is not shown to allow viewing of interior features. The material removal tool 10 includes an actuating body 100 in which a piston head 102 is internally positioned in an actuating chamber (not shown). A translating bar 104 includes a first end operably connected to the piston head 102 to axially translate (T) along a first axis 106 between a first position and a second position when the piston head 102 translates. The translating bar 104 can be connected to the piston head 102 by any suitable means. The piston head 102 translates by an actuating fluid. Actuating fluid is supplied above the piston head 102 and vented from below the piston head (and vice versa) via internal passages, which are supplied and vented through spindle. The actuating fluid can be a liquid or a gas. In an exemplary embodiment, the actuating fluid is a liquid and can, in some embodiments, be a liquid that is also used as a coolant by the material removal tool 10 .
[0024] At pressure, the actuating fluid above the piston head 102 overcomes the biasing force of biasing elements. In exemplary embodiments, the biasing element is preloaded to exert a force to bias the piston head toward the second end 32 of the material removal tool 10 , although the opposite arrangement can also be constructed. Examples of biasing elements include mechanical systems, such as springs, dashpots, pistons and bellows, elastic materials, and non-mechanical systems, such as compressible fluids and compressible gases. Biasing can be accomplished by any desired technique. For example, a mechanical biasing element, such as a spring, can be used.
[0025] The translating bar 104 includes an actuating surface 108 at a second end or a plurality of actuating surfaces 108 spaced axially along the translating bar 104 . In exemplary embodiments, the actuating surface 108 has an outer surface having the shape of a cone or frustum. The actuating surface 108 is formed of a hard, wear resistant material, such as cemented carbide. In exemplary embodiments, the actuating surface 108 onto the translating bar, although any suitable attachment means can be used. The actuating surface can be polished to a desired smoothness. A suitable smoothness for the actuating surface is about (i.e., ±10%) 4 RMS.
[0026] Also shown in FIG. 2 is the plurality of cartridges 14 . The plurality of cartridges 14 is secured in the housing body (not shown) by any suitable mounting mechanism 110 , such as fastener, a cap screw, a bolt or a screw. The cartridge 14 itself is securely mounted relative to the housing body 12 . However, the seating members 18 are pivotable about an axis 112 . The pivoting of the seating members 18 is actuated by translation of the translating bar 104 operating through actuating surface 108 contacting push pin 114 . Although the term pin is used, the push pin can take any geometric shape, such as, for example, curved geometric shapes, and regular and irregular polygonal shapes. The actuating surface 108 has a variable radius along a set axial distance. As the actuating surface 108 moves relative to the push pin 114 , the radial position of the end of the push pin 114 along a second axis changes in correlation to the variable radius of the actuating surface 108 . This change in radial position of the end of the push pin 114 then directly or indirectly changes the position of or creates a force operating on the pivotable seating member 18 . Therefore, as the translating bar axially translates between a first position and a second position when the piston head translates, the plurality of seating members move from a first position, i.e., a retracted position, to a second position, i.e., an extended position. In FIG. 2 , the cutting inserts 24 are shown in stand-off relationship to the seating members 18 to show the pockets 20 .
[0027] Turning to FIG. 3 , which is a magnified view of the arrangement of some of the internal components, the relative positions of the cartridge 14 , the seating members 18 , axis 112 , translating bar 104 , actuating surface 108 and push pin 114 can be observed more clearly. For example, each of the seating members 18 has a separate push pin 114 . An adjustment screw 116 in the seating member 18 protrudes inward from the seating member and has an end that contacts the end of the push pin 114 . As such, the adjustment screw 116 can be used for fine adjustment of the radial position of the seating member 18 . Multiple locating pins 120 are shown distributed circumferentially about the translating bar 104 . These locating pins 120 can be used to support and center the translating bar 104 .
[0028] Turning to the cartridge 14 , such as exemplary illustrated in top plan view in FIG. 4 , the cartridge 14 comprises a body 200 with a cavity 202 in which the pivotable seating members 18 are removably mounted. The cavity 202 is open on two sides of the cartridge 14 to facilitate manufacture and assembly, but other embodiments can have a cavity open to one side, three sides, or more, depending on design. As seen in FIG. 4 , the pivotable seating members 18 share a common pivot axis 204 . However, the pivotable seating members 18 can alternatively have different pivot axes. Here, the pivotable seating members 18 share a common pivot axis 204 by each of the pivotable seating members cooperating with only a portion of the axis 204 to pivot. As seen in FIG. 4 , the pivotable seating member 18 is only half-width in the area of the axis 204 so that the pivotable seating members 18 stack next to each other along the axis 204 . In the FIG. 4 embodiment, a closure plate 206 is attached to the body 200 and assists in positioning the pivotable seating members 18 and the associated pivot axis 204 . Further, the closure plate 206 has openings 208 to allow mounting, indexing and exchanging of cutting inserts in the pocket 20 . In one exemplary embodiment and as seen in the side plan view of FIGS. 6A and 6B . the openings 208 are similar to crenellations, but any suitable geometry of the openings 208 can be used that allows access to the pocket 20 .
[0029] The cartridge 14 can optionally include adjusting features for both axial and radial positioning. For example, the cartridge can include an axial locating device, such as a locating screw 210 , which can be adjusted to change the axial position of the cartridge 14 in the enclosed pockets 16 . The enclosed pockets 16 provide a mounting mechanism for the cartridges 14 that leaves a maximum amount of the housing body intact to provide stiffness and strength from the mass of the housing body. Non-enclosed pockets can also be used if the housing body is sufficiently large and/or of sufficient mass to obtain the desired stiffness. A similar radial locating device can also be utilized. In regard to the radial adjustment of the pivotable seating member 18 , reference is made to the adjustment screw 116 , which was previously shown and described and is shown more clearly in FIGS. 4 and 5 .
[0030] FIG. 5 is a disassembled, perspective view of a cartridge 14 with pivotable seating members 18 . In addition to the features of the cartridge 14 previously shown and described, FIG. 5 also shows the biasing element 212 , which acts on an end surface 214 of the individual seating members 18 to bias the seating member 18 in a retracted position, and the axle pin 216 about which the seating members 18 pivot and more clearly shows the adjustment screw 116 and the pocket 20 with the seating surface 22 (the pocket and seating surface on the second seating member 18 is not labeled for clarity).
[0031] FIGS. 6A and 6B show the seating members 18 (and associated cutting inserts 24 ) in a retracted position ( FIG. 6A ) and in an extended position ( FIG. 6B ). In the retracted position ( 6 A), a biasing member, such as a torsional spring positioned about the axis or an axial spring positioned to perate lever-like on a surface of the seating member, biases the seating member 18 in the retracted position. In the extended position ( FIG. 6B ), the seating members 18 have been moved radially outward and pivoted inward toward each other in a scissor-like motion (M) by operation of the push pin 114 contacting the adjustment screw 116 and being moved radially outward by the change in radial position of the actuating surface 108 of the translating bar 104 . Pivoting the seating members 18 between the retracted and extended positions can be either simultaneous or sequential and can be controlled based on the design and operation of the translating equipment such as the translating bar and actuating surfaces. A typically radial difference between the retracted position and the extended position is on the order of millimeters, e.g., 1-3 millimeters or about 1.5 millimeters. Furthermore, the seating members 18 in any one cartridge 14 do not have to be at the same radial distance in either the retracted or extended positions.
[0032] FIGS. 7A to 7C illustrate different operating positions for the pivotable seating members (and associated cutting inserts) while machining a workpiece. In the illustrated example, the workpiece 300 is a crank shaft bearing support and is shown in partial view; similarly, only a portion of the material removal tool 10 is shown.
[0033] FIG. 7A illustrates a starting position for removing material from the workpiece. An active portion of the material removal tool 10 is inserted into a bore of the workpiece 300 . The active portion is positioned relative to the workpiece to position a surface 302 of the workpiece to be machined radially proximate a pivot axis 204 of a plurality of seating members 18 mounted in a cartridge mounted on the active portion of the material removal tool. Because the illustrated cartridges is mounted in an enclosed pocket, the cartridge is not visible in the FIGS. 7A to 7C views. As seen in the FIG. 7A view and for this material removal operation, the two cutting inserts 24 in any one cartridge are in an initial retracted position and are on opposite sides of the workpiece 300 . In the retracted position, the outermost surface of the cutting insert 24 is at a distance d 1 from the surface of the seating member 18 (see FIG. 6A ).
[0034] The plurality of seating members are then actuated to pivot to an extended position and the rotating material removal tool is translated in a first axial direction T 1 . In the extended position, the outermost surface of the cutting insert 24 is at a distance d 2 from the surface of the seating member 18 (see FIG. 6B ), where d 2 is greater than d 1 . This movement contacts the extended cutting insert 24 mounted in a pocket of a first of the plurality of seating members with the surface 302 of the workpiece to be machined and removes some of the material. FIG. 7B shows the material removal tool with the seating members in the extended position and after translating the tool in the first axial direction, i.e., at the completion of the first machining operation.
[0035] Subsequently, the material removal tool is axially translated in a second axial direction T 2 . This movement contacts the extended cutting insert 24 mounted in a pocket of a second of the plurality of seating members with the surface 302 of the workpiece to be machined and removes some of the material. FIG. 7C shows the material removal tool with the seating members in the extended position and after translating the tool in the second axial direction, i.e., at the completion of the second machining operation.
[0036] Because the radial position of the cutting insert mounted in a pocket of a second of the plurality of seating members are greater than the radial position of the cutting insert mounted in a pocket of a first of the plurality of seating members, the first cutting operation removes some material and the second cutting operation removes more material. In addition, the different cutting operations allow use of different cutting insert types. For example, the cutting insert mounted in a pocket of a first of the plurality of seating members can be a semi-finish cutting insert and the cutting insert mounted in a pocket of a second of the plurality of seating members can be a finish cutting insert. The above method forms a finished surface of the bore in one stroke of the material removal tool, i.e., a forestroke and a backstroke.
[0037] The above first and second cutting operations have been described with the plurality of seating members extending once and retracting once. In such an operation, the first cutting insert 24 potentially contacts the surface 302 of the workpiece to be machined during both translation in the first axial direction and translation in the second axial direction. This can cause undesirable cutting defects during the backstroke. As an alternative, the seating members can be actuated more times. For example, after translating the rotating material removal tool in the first axial direction and before contacting the surface with the second cutting insert, preferably before translation in the second axial direction begins, the plurality of seating members are actuated to pivot the plurality of seating members to a retracted position. This disengages the first cutting insert from the surface of the workpiece or from potentially contacting the surface of the workpiece. The rotating material removal tool is then partially translated in the second axial direction to move the first cutting insert past the workpiece, and the plurality of seating members are reactuated to pivot the plurality of seating members to the extended position. Translation in the second axial direction is then completed with the cutting insert 24 mounted in a pocket of a second of the plurality of seating members contacting the surface 302 of the workpiece to be machined and removing some of the material.
[0038] After completion of cutting operations, the plurality of seating members are actuated to pivot the plurality of seating members to a retracted position and the active portion of the material removal tool can be withdrawn from the bore of the workpiece.
[0039] To further ensure against unwanted contact between the cutting inserts and the workpiece during operation, in the retracted position, the plurality of seating members are each inward of an outermost surface of the active portion, and wherein in the extended position, the plurality of seating members are each outward of the outermost surface of the active portion.
[0040] Although only one cutting position is shown in FIGS. 7A to 7C , the same cutting operations can be accomplished at multiple cutting positions of the material removal tool to cut multiple bores simultaneously utilizing multiple inserts per bore.
[0041] Benefits of the disclosed material removal tool includes balanced cutting forces (as compared to single point cutting) and longer tool life between insert changes. In addition, because the forward and back stroke is minimized by the closer positioning of the two cutting inserts relative to each other, non-cutting time is reduced and cutting operations are more efficient.
[0042] In an optional embodiment, the cartridge can include only one pivotable seating member, with suitable features as shown and described herein with respect to cartridges with a plurality of pivotable seating members. FIG. 8 is a schematic drawing of an exemplary embodiment of a material removal tool with an alternative exemplary embodiment of a cartridge with a single pivotable seating member. In the FIG. 8 view, a material removal tool 400 has a plurality of cartridges 402 with a single pivotable seating member 404 . One of the cartridges 402 is shown in disassembled, perspective view and the individual components thereof can be viewed. Cutting operations using the material removal tool 400 with a cartridge 402 with only one pivotable seating member 404 can be completed in a single axial translation of the material removal tool, with suitable other operations, actuations, extensions and retractions as shown and described herein with respect to cutting operations with material removal tools with cartridges with a plurality of pivotable seating members. The alternative embodiment of the cartridge 402 including only one pivotable seating member 404 can be used, for example, on material removal tools with active portions defined by short axial lengths that may only accommodate such cartridges, which can occupy a shorter axial length of the active portion due to having only a single pivotable seating member.
[0043] Although described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without department from the spirit and scope of the invention as defined in the appended claims. | 4y
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This application is a divisional of Ser. No. 08/668,560, filed Jun. 21, 1996, now U.S. Pat. No. 6,019,987, which is it self a divisional of Ser. No. 08/217,187, filed Mar. 24, 1994, now U.S. Pat. No. 5,554,506.
FIELD OF THE INVENTION
This invention relates to immunogenetics and to peptide chemistry. More particularly, it relates to peptides, such as nonamers, decamers, and undecamers useful in various ways, including immunogens and as ligands for the HLA-A2 molecule. More particularly, it relates to a so-called “tumor rejection antigen”, derived from the tumor rejection antigen precursor encoded by gene MAGE-3, and presented by MHC-class I molecule HLA-A2.
BACKGROUND AND PRIOR ART
The study of the recognition or lack of recognition of cancer cells by a host organism has proceeded in many different directions. Understanding of the field presumes some understanding of both basic immunology and oncology.
Early research on mouse tumors revealed that these displayed molecules which led to rejection of tumor cells when transplanted into syngeneic animals. These molecules are “recognized” by T-cells in the recipient animal, and provoke a cytolytic T-cell response with lysis of the transplanted cells. This evidence was first obtained with tumors induced in vitro by chemical carcinogens, such as methylcholanthrene. The antigens expressed by the tumors and which elicited the T-cell response were found to be different for each tumor. See Prehn, et al., J. Natl. Canc. Inst. 18: 769-778 (1957); Klein et al., Cancer Res. 20: 1561-1572 (1960); Gross, Cancer Res. 3: 326-333 (1943), Basombrio, Cancer Res. 30: 2458-2462 (1970) for general teachings on inducing tumors with chemical carcinogens and differences in cell surface antigens. This class of antigens has come to be known as “tumor specific transplantation antigens” or “TSTAs”. Following the observation of the presentation of such antigens when induced by chemical carcinogens, similar results were obtained when tumors were induced in vitro via ultraviolet radiation. See Kripke, J. Natl. Canc. Inst. 53: 333-1336 (1974).
While T-cell mediated immune responses were observed for the types of tumor described supra, spontaneous tumors were thought to be generally non-immunogenic. These were therefore believed not to present antigens which provoked a response to the tumor in the tumor carrying subject. See Hewitt, et al., Brit. J. Cancer 33: 241-259 (1976).
The family of tum − antigen presenting cell lines are immunogenic variants obtained by mutagenesis of mouse tumor cells or cell lines, as described by Boon et al., J. Exp. Med. 152: 1184-1193 (1980), the disclosure of which is incorporated by reference. To elaborate, tum − antigens are obtained by mutating tumor cells which do not generate an immune response in syngeneic mice and will form tumors (i.e., “tum + ” cells). When these tum + cells are mutagenized, they are rejected by syngeneic mice, and fail to form tumors (thus “tum − ”). See Boon et al., Proc. Natl. Acad. Sci. USA 74: 272 (1977), the disclosure of which is incorporated by reference. Many tumor types have been shown to exhibit this phenomenon. See, e.g., Frost et al., Cancer Res. 43: 125 (1983).
It appears that tum variants fail to form progressive tumors because they initiate an immune rejection process. The evidence in favor of this hypothesis includes the ability of “tum−” variants of tumors, i.e., those which do not normally form tumors, to do so in mice with immune systems suppressed by sublethal irradiation, Van Pel et al., Proc. Natl. Acad. Sci. USA 76: 5282-5285 (1979); and the observation that intraperitoneally injected tum cells of mastocytoma P815 multiply exponentially for 12-15 days, and then are eliminated in only a few days in the midst of an influx of lymphocytes and macrophages (Uyttenhove et al., J. Exp. Med. 152: 1175-1183 (1980)). Further evidence includes the observation that mice acquire an immune memory which permits them to resist subsequent challenge to the same tum − variant, even when immunosuppressive amounts of radiation are administered with the following challenge of cells (Boon et al., Proc. Natl, Acad. Sci. USA 74: 272-275 (1977); Van Pel et al., supra; Uyttenhove et al., supra).
Later research found that when spontaneous tumors were subjected to mutagenesis, immunogenic variants were produced which did generate a response. Indeed, these variants were able to elicit an immune protective response against the original tumor. See Van Pel et al., J. Exp. Med. 157: 1992-2001 (1983). Thus, it has been shown that it is possible to elicit presentation of a so-called “tumor rejection antigen” in a tumor which is a target for a syngeneic rejection response. Similar results have been obtained when foreign genes have been transfected into spontaneous tumors. See Fearon et al., Cancer Res. 48: 2975-1980 (1988) in this regard.
A class of antigens has been recognized which are presented on the surface of tumor cells and are recognized by cytolytic T cells, leading to lysis. This class of antigens will be referred to as “tumor rejection antigens” or “TRAs” hereafter. TRAs may or nay not elicit antibody responses. The extent to which these antigens have been studied, has been via cytolytic T cell characterization studies, in vitro i.e., the study of the identification of the antigen by a particular cytolytic T cell (“CTL” hereafter) subset. The subset proliferates upon recognition of the presented tumor rejection antigen, and the cells presenting the antigen are lysed. Characterization studies have identified CTL clones which specifically lyse cells expressing the antigens. Examples of this work may be found in Levy et al., Adv. Cancer Res. 24: 1-59 (1977); Boon et al., J. Exp. Med. 152: 1184-1193 (1980); Brunner et al., J. Immunol. 124: 1627-1634 (1980); Maryanski et al., Eur. J. Immunol. 124: 1627-1634 (1980); Maryanski et al., Eur. J. Immunol. 126: 406-412 (1982); Palladino et al., Canc. Res. 47: 5074-5079 (1987). This type of analysis is required for other types of antigens recognized by CTLs, including minor histocompatibility antigens, the male specific H-Y antigens, and the class of antigens referred to as “tum 31 ” antigens, and discussed herein.
A tumor exemplary of the subject matter described supra is known as P815. See DePlaen et al., Proc. Natl. Acad. Sci. USA 85: 2274-2278 (1988); Szikora et al., EMBO J 9: 1041-1050 (1990), and Sibille et al., J. Exp. Med. 172: 35-45 (1990), the disclosures of which are incorporated by reference. The P815 tumor is a mastocytoma, induced in a DBA/2 mouse with methylcholanthrene and cultured as both an in vitro tumor and a cell line. The P815 line has generated many tum variants following mutagenesis, including variants referred to as P91A (DePlaen, supra), 35B (Szikora, supra), and P198 (Sibille, supra). In contrast to tumor rejection antigens—and this is a key distinction—the tum 31 antigens are only present after the tumor cells are mutagenized. Tumor rejection antigens are present on cells of a given tumor without mutagenesis. Hence, with reference to the literature, a cell line can be tum + , such as the line referred to as “P1”, and can be provoked to produce tum − variants. Since the tum − phenotype differs from that of the parent cell line, one expects a difference in the DNA of tum − cell lines as compared to their tum + parental lines, and this difference can be exploited to locate the gene of interest in tum − cells. As a result, it was found that genes of tum − variants such as P91A, 35B and P198 differ from their normal alleles by point mutations in the coding regions of the gene. See Szikora and Sibille, supra, and Lurguin et al., Cell 58: 293-303 (1989). This has proved not to be the case with the TRAs of this invention. These papers also demonstrated that peptides derived from the tum − antigen are presented by the L d molecule for recognition by CTLs. P91A is presented by Ld, P35 by D d and P198 by K d .
PCT application PCT/US92/04354, filed on May 22, 1992 assigned to the same assignee as the subject application, teaches a family of human tumor rejection antigen precursor coding genes, referred to as the MAGE family. Several of these genes are also discussed in van der Bruggen et al., Science 254: 1643 (1991). It is now clear that the various genes of the MAGE family are expressed in tumor cells, and can serve as markers for the diagnosis of such tumors, as well as for other purposes discussed therein. See also Traversari et al., Immunogenetics 35: 145 (1992); van der Bruggen et al., Science 254: 1643 (1991). The mechanism by which a protein is processed and presented on a cell surface has now been fairly well documented. A cursory review of the development of the field may be found in Barinaga, “Getting Some ‘Backbone’: How MHC Binds Peptides”, Science 257: 880 (1992); also, see Fremont et al., Science 257: 919 (1992); Matsumura et al., Science 257: 927 (1992); Latron et al., Science 257: 964 (1992). These papers generally point to a requirement that the peptide which binds to an MHC/HLA molecule be nine amino acids long (a “nonapeptide”), and to the importance of the first and ninth residues of the nonapeptide.
Studies on the MAGE family of genes have now revealed that a particular nonapeptide is in fact presented on the surface of some tumor cells, and that the presentation of the nonapeptide requires that the presenting molecule be HLA-A1. Complexes of the MAGE-1 tumor rejection antigen (the “TRA” or nonapeptide”) leads to lysis of the cell presenting it by cytolytic T cells (“ICTLs”). Attention is drawn, e.g., to, concurrently filed application Ser. No. 08/217,186 now U.S. Pat. No. 5,585,461 to Townsend, et al., and Ser. No. 08/217,186 now U.S. Pat. No. 5,554,724 to Melief, et al., both of which present work on other, MAGE-derived peptides. Research presented in, e.g., U.S. Pat. No. 5,405,940 and in U.S. Pat. No. 5,462,871, when comparing homologous regions of various MAGE genes to the region of the MAGE-1 gene coding for the relevant nonapeptide, there is a great deal of homology. Indeed, these observations lead to one of the aspects of the invention disclosed and claimed therein, which is a family of nonapeptides all of which have the same N-terminal and C-terminal amino acids. These nonapeptides were described as being useful for various purposes which includes their use as immunogens, either alone or coupled to carrier peptides. Nonapeptides are of sufficient size to constitute an antigenic epitope, and the antibodies generated thereto were described as being useful for identifying the nonapeptide, either as it exists alone, or as part of a larger polypeptide.
These references, especially U.S. Pat. No. 5,462,871, showed a connection between HLA-A1 and RAGE-3; however, only about 26% of the Caucasian population and 17% of the negroid population presents HLA-A1 molecules on cell surfaces. Thus, it would be useful to have additional information on peptides presented by other types of MHC molecules, so that appropriate portions of the population may benefit from the research discussed supra.
It has now been found that antigen presentation of MAGE-3 derived peptides is not limited to HLA-A1 molecules. The invention set forth, in the disclosure which follows, identifies peptides which complex with MHC class I molecule HLA-A2. The ramifications of this discovery, which include therapeutic and diagnostic uses, are among the subjects of the invention, set forth in the disclosure which follows.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE 1
The sequence of the MAGE-3 gene is known, as per Ser. No. 08/037,230, e.g., and PCT/US92/04354, e.g., both of which are referred to supra, and are incorporated by reference in their entirety. Similarly, it is known that HLA-A1- cells, transfected with a nucleic acid molecule coding for MAGE-3 are lysed by cytolytic T cells (see, e.g. Ser. No. 08/037,230, the disclosure of which is incorporated by reference in its entirety; also, see U.S. Pat. No. 5,462,871, the disclosure of which is incorporated by reference in its entirety).
These findings suggested a review of the amino acid sequence coded for by the MAGE-3 gene, together with the scoring system developed by Nijman et al., Eur. J. Immunol. 23: 1215 (1993), incorporated by reference in its entirety, to identify peptides derived from MAGE-3 which, putatively, bind to the HLA-A2 MHC molecule. This reference, in brief, describes a system where “anchor”, “strong” and “weak” amino acids may be found along a peptide. Anchor positions are at the second and ninth amino acids. There are three possible positions where a strong amino acid can be placed, and four where a weak amino acid may be placed. The maximum score possible for a nonamer is 6 2 ×4 3 ×2 4 , or 36,864. Such peptides were identified, and are the peptides referred to hereafter.
EXAMPLE 2
The peptides identified via the protocol set forth supra were synthesized using a protein synthesizer, and were dissolved in 0.9% NaCl, 5% DMSO (or 5% DMF for the peptide SEQ ID NO: 3), at 0.5 mM. These peptide solutions were stored at −80° C. until ready for use.
To determine whether or not peptides bound to HLA-A2 molecules, cell line 174 CEM.T2 (hereafter “T2”) was used. This cell line is described by Cerundolo et al., Nature 345: 449-452 (1990), and Spies et al., Nature 348: 744-747 (1990), the disclosures of which are incorporated by reference. This is a cell line deficient in the pathway which supplies peptides to the endoplasmic reticulum, the site of assembly of MHC class I heterodimers. It can assemble MHC class-I molecules, but these are unstable, and, on cell lysis, dissociate into free heavy and light chains during overnight incubation. The heterodimers can, however, be stabilized in vitro via addition of appropriate peptide ligands, as per Townsend et al., Nature 340: 443-448 (1989); Townsend et al., Cell 62: 285-195 (1990); Cerundolo et al., supra; Schumacher et al., Nature 350: 703-706 (1991); Elliot et al., Nature 351: 402-406 (1991); Elvin et al., Eur. J. Immunol. 21 : 2025-2031 (1991). The thus stabilized molecules can be immunoprecipitated with antibodies specific for the MHC class-I molecule.
In light of this background, the T2 cells were washed in serum free IMDM medium, and then 1.0×10 6 cells were suspended in 400 ul of the serum free IMDM medium, together with 100 ul synthetic peptide (final concentration: 0.1 mM, 1% DMSO). The mixture was incubated, overnight, at 37° C. Following incubation, the cells were washed and stained, successively, with HLA-A2 specific monoclonal antibody BB7.2, and FITC labelled, binding fragments of polyclonal goat anti-mouse IgG. Fluorescence ratio was calculated by the following formula: Mean fluorescence of the experimental sample Mean fluorescence of the background
This yielded the “mean fluorescence ratio” or MFR. In accordance with Nijman et al, supra, an MFR greater than 1.5 indicates binding to HLA-A2.
Five peptides were identified which were predicted to bind specifically to the HLA-A2 molecules. These five were tested in the assay described above, and three of them, i.e., SEQ ID NOS: 1, 3 and 4 were found to bind to HLA-A2 molecules. Each had an MFR value greater than the 1.5 value, i.e.
Peptide
MFR
M3-44.53
TLVEVTLGEV (SEQ ID NO: 1)
3.5
M3-108.116
ALSRKVAEL (SEQ ID NO: 2)
2.17 (and, less than
1.5)
M3-195.203
IMPKAGLLI (SEQ ID NO: 3)
2.37
M3-220.228
KIWEELSVL (SEQ ID NO: 4)
2.37
M3-277.286
ALVETSYVKV (SEQ ID NO: 5)
1.8 (and, less than
1.5)
The peptides M3108.116 and M3-277.286 had MFRs less than 1.5 in some of the experimental runs, and were-not considered further.
EXAMPLE 3
The results obtained in Example 2 suggested further experiments, and peptide M3-220.228 was used to generate a cytolytic T cell clone, referred to hereafter as CTL 4.2. The CTL clone was obtained using T2 cells, in accordance with Houbiers et al., Eur. J. Immunol. 23: 2072 (1993), previously incorporated by reference in its entirety.
Once the CTL clone was isolated, it was used in a chromium release assay in accordance with Boon, et al., J. Exp. Med. 152: 1184 (1980) the disclosure of which is incorporated by reference in its entirety. In addition to T2, cell line SK23, which is an HLA-A2 presenting line, was tested. The results are presented below:
Effector Cell (E): CTL 4.2 Target (T): HLA-A2 cell plus SEQ ID NO: 4
% 51 CR Release
E/T RATIO
T2
T2 + peptide
SK23
SK23 + Peptide
30
0
91
0
35
7.5
0
88
−1
33
1.9
−1
84
−1
14
0.5
−1
57
−1
2
These data show that target cells, pulsed with SEQ ID NO: 4, are specifically lysed by the cytolytic T cell clone 4.2. No lysis occurs in the absence of the peptide.
The foregoing describes the identification of peptides derived from the MAGE-3 tumor rejection antigen precursor which interact with MHC class I molecule HLA-A2. Of particular interest, and a part of the subject matter of the present invention, are the peptides represented by SEQ ID NO: 3 and SEQ ID NO: 4. These peptides are easily synthesized via Merrifield or other peptide synthesis methodologies, and thus isolated peptides of SEQ ID NO: 3 and SEQ ID NO: 4 are a feature of the invention described herein.
The peptides, as indicated, complex with HLA-A2 molecules, and these complexes have been immunoprecipitated, thus leading to another feature of the invention, which is isolated complexes of the HLA-A2 molecule and either one of these peptides.
Both the peptides and the complexes are useful in various ways. As was shown, the peptides bind to the HLA-A2 molecule, and thus they are useful in assays to determine whether or not HLA-A2 presenting cells are present in a sample. The peptide is contacted to the sample of interest in some determinable form, such as a labelled peptide (radiolabel, chromophoric label, and so forth), or bound to a solid phase, such as a column or an agarose or SEPHAROSE bead, and the binding of cells thereto determined, using standard analytical methods.
Both the peptides and the isolated complexes may be used in the generation of monoclonal antibodies or cytolytic T cell clones specific for the aforementioned complexes. Those skilled in the art are very familiar with the methodologies necessary to accomplish this, and the generation of a cytolytic T cell clone is exemplified supra. As cancer cells present complexes of MAGE-3 derived peptides of SEQ ID NO: 3 or SEQ ID NO: 4 and HLA-A2, these monoclonal antibodies and cytolytic T cells clones serve as reagents which are useful in diagnosing cancer. The chromium release assay discussed supra is exemplary of assays which use CTLs to determine targets of interest, and the art is quite familiar with immunoassays and how to carry these out.
Cytolytic T cell clones thus derived are useful in therapeutic milieux such as adoptive transfer. See Greenberg, J. Immunol. 136(5): 1917 (1986); Reddel et al., Science 257: 238 (1992); Lynch et al., Eur. J. Immunol. 21: 1403 (1991); Kast et al., Cell 59: 603 (1989), all of which are incorporated by reference herein. In this methodology, the peptides set forth supra are combined with antigen presenting cells (“APCs”), to form stable complexes. Many such methodologies are known, for example, those disclosed in Leuscher et al., Nature 351: 72-74 (1991); Romero et al., J. Exp. Med. 174: 603-612 (1991); Leuscher et al., J. Immunol. 148: 1003-1011 (1992); Romero et al., J. Immunol. 150: 3825-3831 (1993); Romero et al., J. Exp. Med. 177: 1247-1256 (1993), and Romero et al., U.S. patent application Ser. No. 133,407, filed Oct. 5, 1993 and incorporated by reference herein. Following this, the presenting cells are contacted to a source of cytolytic T cells to generate cytolytic T cell clones specific for the complex of interest. Preferably, this is done via the use of an autologous T cell clone, found in, for example, a blood sample, taken from the patient to be treated with the CTLs. Once the CTLs are generated, these are reperfused into the subject to be treated in an amount sufficient to ameliorate the cancerous condition, such as by lysing cancer cells, inhibiting their proliferation, etc.
Other aspects of the invention will be clear to the skilled artisan and need not be reiterated here.
The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, it being recognized that various modifications are possible within the scope of the invention.
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This a continuation in-part of application Ser. No. 07/920,399, filed Jul. 29, 1992, now U.S. Pat. No. 5,302,177, issued Apr. 12, 1994.
BACKGROUND OF THE INVENTION
This invention relates generally to the controlled cooling of the molten flat glass ribbon as it passes through the tin float bath at a continuous rate. Manufacturing flat glass comprises the delivering of molten glass to a bath of molten tin and advancing the glass along the surface of the tin under thermal conditions that do not contaminate the internal atmosphere. Such contamination is detrimental to both the glass product and the molten tin. Glass at approximately 1900 degrees F enters the bath from the melting tank and at approximately 1200 degrees F exits the bath to a cooling lehr. In prior art installations the temperatures in the bath are maintained with electrical resistance heaters suspended from the roof over the ribbon of glass. Such electrical heaters do not contaminate the bath atmosphere. The metal plate shell of the prior art bath roof is protected from the heat with an internal refractory lining, which has little or no heat-insulating qualities and isolates the electrical equipment plenum above from the heated cavity. This prior art construction has been used over the past twenty-five year period. Attempts to burn natural gas over the bath by the glass industry failed the industry's contamination requirements.
PRIOR ART
______________________________________PatentsNumber Date Relationship______________________________________3,083,551 04.02.63 Layout of float with molten metal3,332,763 07.25.67 Layout of tin float bath utilizing electrical heating elements3,486,869 12.30.69 Layout of tin float bath utilizing regular and auxiliary electrical heating elements______________________________________
Reference Material (To assist in understanding the presentation)
The Handbook of Glass Manufacture, volume II, 3 rd edition, pages 714-2 through 714-21
The Glass Industry Magazine, April 1980 issue, pages 18,20,22, article "Float Glass Production: Pilkington vs PPG," by Ronald A. MeCauley, Rutgers University.
A Review Lecture, "The float glass process," by L. A. B. Pilkington, delivered Feb. 13, 1949.
Reference Drawings, sheet 1 with FIGS. 1 and 2 and sheet 2 with FIG. 3 showing the existing electrical tin float bath.
Prior art uses electrical heating elements with intricate power supplies, conductors, contactors and controls. The present invention's use of a natural gas system with automatic recuperative burners surpasses the prior art by bring more cost-efficient and more energy-efficient, does not contaminate the bath atmosphere, is more easily installed, minimizes maintenance and shut-down, all of which promotes increased productivity.
SUMMARY OF THE INVENTION
The construction of an entirely new operational roof for the tin float bath comprises two parts, the newly designed fabrication of the bath roof and the use of automatic recuperative natural gas burners instead of the prior art electrical heating elements. Individually, both the new fabrication and gas burners contribute to a cost-efficient operation that highly excels the prior art operation.
The fabrication of the new roof housing utilizes a one-half inch steel plate furnace shell of a required depth to allow the installation of the gas burners in either a horizontal or a vertical position. The interior insulation of the new furnace shell consists of a layered ceramic fiber lining of blanket modules sold commercially as "Firewall Bonded 22," and two one-inch thick boards sold commercially as "Fiberfrax Duraboard," type, maintaining a temperature differential from 2200 degrees F. inside the shell to an approximately 200 degrees F. outside the shell. No cooling chamber is required above the new bath enclosure as is necessary to protect the prior art electrical equipment and materials of the prior art tin float bath. Such cooling chamber causes a condensation of tin oxide/tin sulfide on the suspended internal refractory lining which then becomes a contaminate of the glass.
The use of the new automatic recuperative natural gas burners in the tin float bath process will result in the following operational cost advantages. The utilization of natural gas is more cost-efficient than electricity, approximately a conservative seventy percent savings in this case. The new gas burner installation encompasses few moving parts, easy insertion of the burners through the mounting flange even during full operation, only two piping connections for gas and combustion air, and simple HIGH-FIRE, LOW-FIRE, OFF control. Glass production is a twenty-four hour daily operation throughout the mechanical life of the bath. Burned out or broken electrical heaters periodically cause prior art operational adjustments to maintain glass flow until quality is affected and complete shut down then becomes necessary. Any shutdown costs are prohibitive, thousands of dollars per minute. Prior art shutdowns entail stopping the glass flow, cooling the bath, raising the roof, replacing the failed electrical heaters with new, making electrical reconnections, lowering the roof, reheating the bath and again establishing the glass flow in its proper atmosphere. This prior art shutdown encompasses engineering, demolition and installation for a ninety day period during which no glass is produced. With the new automatic recuperative gas burners no shutdown is necessary. Seldom will the gas burners fail. If one does require replacement, it can be readily removed and replaced. This replacement will take approximately two hours, during which time the glass flows continuously with no interruptions. The longevity of the installation is increased substantially because, first, the new burners are capable of withstanding the corrosive nature of tin oxide/tin sulfide and, also, the new layered ceramic fiber lining does not deteriorate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a prior art tin float bath chamber showing heating zones and electrical heating transformers.
FIG. 2 is a longitudinal elevation of a prior art tin float bath showing the bath chamber roof and the bath bottom and the heating transformers mounted on the roof support structure.
FIG. 3 is a transverse section of a prior art tin float bath chamber taken along line 3--3 of FIG. 1 detailing the electrical materials and equipment. This section is typical throughout the length of the prior art bath.
FIG. 4 is a plan view of the new elongated tin float bath chamber showing how the electrical installation and the prior art bath roof of FIG. 1 has been omitted and replaced with the new bath roof and the natural gas burners arranged parallel to each other.
FIG. 5 is a longitudinal elevation of the new tin float bath chamber showing the new side mounted natural gas burners.
FIG. 6 is a transverse section of the new tin float bath taken at the plan line 6--6 of FIG. 4 showing the absence of the electrical heating materials, equipment and the prior art bath roof, and their replacement with the new bath roof and the new side-mounted natural gas burners.
FIG. 7 is similar to FIG. 6 except with top vertical mounted new natural gas burners. Either section or both is typical throughout the length of the new bath.
FIG. 8 is a detail of the construction of the new bath roof with sinusoidal layered ceramic fiber blanket lining.
FIG. 9 is a detailed cutaway view of the new automatic recuperative natural gas burner.
FIG. 10 is a piping and instrumentation diagram showing the natural gas supply pipe with its main gas valve train, the natural gas header pipe, the combustion air blower, the combustion air header pipe, associated valves, and with the requisite taps, adjustable valves, burners and instruments. FIG. 10 is typical of all zones having four burners. Zones with six, seven or eight burners are provided similarly and from the same gas and air headers. See FIG. 11 for the quantity of burners per zone.
FIG. 11 is a heating conversion chart showing the connected kilowatts, the quantity of the prior art electrical heating elements, the total rated BTU's for each of the prior art thirty-two electrical zones of the prior art tin float bath, the proposed burner zone BTU requirements, the quantity of burners per burner zone, burner information and total BTU's for each of the twenty-four gas burner zones. This chart presents the calculated natural gas requirements to operate the new tin float bath and to determine how cost efficient and energy efficient the new bath is as opposed to the prior art bath. See FIG. 12 for comparative costs.
FIG. 12 is a bath operation cost comparison chart presenting with the total annual cost of operating a prior art bath with electricity and the new bath with natural gas. This does not include the cost savings that will result from the new bath roof with the layered ceramic fiber lining. This savings can be determined only during operation.
FIG. 13 is a chart showing the quantities of the electrical equipment and materials from the prior art tin float bath that will not be included in the installation of the new tin float bath with automatic recuperative gas burners.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An explanation of the prior art tin float bath must precede the detailed presentation of this invention. In order that this invention may be understood more readily, references to the accompanying figures will be made.
FIG. 1 is a plan view of a prior art typical tin float bath chamber with electrical heating zones numbered 1' through 32' and with the associated zone transformers, numbered 1" through 32". Glass enters the bath from the right and exits from the left.
FIG. 2 is a longitudinal elevation of the prior art bath showing the bath roof 33, the bath bottom 34 and the heating transformer locations above.
FIG. 3 is a transverse section taken on the line 3--3 of FIG. 1, detailing the electrical materials internal to the prior art bath roof and consisting of copper bus bars 35 terminating in the bus box 36 and connectors 37. Cables 38 connect bus bars 35 to the electrical heating elements 39 and to the transformers 3" and 8" above. FIG. 3 is typical through the length of the bath. Electrical resistance heaters 39 are shown extended into the bath atmosphere 40 over the glass ribbon 41 floating on the tin 42. The prior art bath roof 33 is suspended separately from the bath bottom 34 by a support structure 43. The prior art bath roof 33 with all of its associated electrical equipment and materials as shown in FIGS. 1, 2 and 3 shall be removed in its entirety and replaced with a new bath roof 331 as shown in FIG. 6. The prior art support structure 43 will remain to support the new bath roof 331. The quantities of electrical items eliminated with the prior art roof are listed on FIG. 13.
FIG. 4 is a plan view of the new elongated tin float bath chamber showing the locations of one hundred eighteen natural gas burners 44 in their respective heating zones in parallel. Glass enters the bath from the right and exits from the left. The new bath roof 331 is shown on FIGS. 5, 6, 7 and 8.
FIG. 5 is a longitudinal elevation of the new elongated tin float bath chamber showing the locations of the natural gas burners 44 mounted through the side walls of the new bath roof 331.
FIG. 6 is a transverse section taken along the line 6--6 of FIG. 4 showing the new bath chamber roof 331 which has depending side walls side-mounted natural gas burners 44 are installed horizontally through the depending side walls of roof 331. Space 45 is allocated for both natural gas and combustion air header pipes.
FIG. 7 shows the natural gas burners 44 installed parallel to each other vertically through the top of the new bath roof 331. Either or both of the horizontal or vertical installations can be utilized and the depth of the new bath roof 331 will be altered accordingly.
FIG. 8 shows the construction details of the new bath roof 331. The shell 80 of the new bath roof is fabricated of one-half inch plate steel and is made rigid with an I-beam and angle framework 84. The shell 80 and the framework 84 are suspended from the support structure 43. The interior of the shell housing is insulated with sinusoidal layers of ceramic fiber blanket modules 81 sold commercially as "Firewall Bonded 22," and two one-inch thick, rigid, high temperature ceramic fiber boards 82 sold commercially as "Fiberfrax Duraboard," type RG, all as manufactured by The Carborundum Company. This insulation provides the following advantages: lower heat losses, faster heat-up and cool-down cycles, lower installed costs, easy repairs, thermal shock resistance, high heat internal reflectance, good sound absorption, excellent corrosion resistance and longer life of the new bath. Side seal blocks 83 seal the void between the new elongated roof 331 and the present elongated bath bottom 34 to form the complete tin float bath chamber. Items 47, 49, 50 and 52 of the burners 44 are described as part of FIG. 9.
FIG. 9 is a cutaway view of the automatic recuperative natural gas burner similar to that as fabricated from an Fe Cr Al alloy known and sold commercially as "Kanthal APM" by Eclipse Combustion of Rockford IL. Each burner consists of an ignition and heat-radiating chamber body 46 for operation up to 2370 degrees F. which encloses the entire burner and has a semi-spherical closed end portion 46a as shown in FIG. 9, a flanged mount 47 welded to the external chamber roof bath steel shell 48, complete with gas inlet 49, air inlet 50, air metering orifice 51, an exhaust outlet 52 and the internals with a burner nozzle 53 within a sleeve 54 coaxial with body 46. This particular burner type is capable of withstanding the corrosive nature of the tin oxide/tin sulfide present in the bath atmosphere.
The preceding paragraph refers primarily to the preparation of the new bath roof. The remaining equipment, instruments, piping and valves are shown on FIG. 10, a typical piping and instrumentation diagram. The explanation of FIG. 10 will describe the operation for the installation with the horizontal burners. The operation with the vertical burners is similar. A four burner zone 7 is shown. Zones with six, seven and eight burners are similar, differing only in the quantity of burners. Two blowers, the main gas supply with valve train, the control valves and instruments provide combustion air and gas to the gas burners on both sides of the bath.
Natural gas is provided via a four inch gas line 54 to the main gas valve train 55, consisting of: two manual shut-off valves, a pressure regulating valve, two electrically-operated manually-reset shut-off valves with electrical interlocks, a vent valve with an electrical interlock and pressure switch with an electrical interlock. All electrical interlocks 78 are connected to the ignition section of the burner control panel. The four inch natural gas line 56 continues from the main gas valve train as the main gas supply header running along total bath length in allocated space 45, FIG. 6.
Combustion air is provided by a centrifugal blower 57 via an eight inch main air supply header 59. A pressure switch 58 with an electrical interlock 79 is utilized to sense correct air header pressure. This eight inch main air supply header 59 continues along total bath length in space 45, FIG. 6.
The four inch main gas supply header 56 along both sides of the length of the bath is tapped at each burner zone location to form a one inch secondary gas header 61. Located at the beginning of the one inch secondary gas header are two valves. The first is the burner zone secondary gas header ON-OFF solenoid valve 62 with an electrical interlock 79. The second is the burner zone secondary gas header proportionator valve 63 with a proportionator impulse line 64 tapped into the secondary air supply header 60. This proportionator valve is required to maintain the proper natural gas to air ratio required for combustion within the automatic recuperative burner 44. The one inch secondary gas header 61 is continued from the proportionator valve and is tapped with a one-half inch line 65 connected to the zone automatic recuperative burner 44. This line is provided with an adjustable valve 66.
The eight inch main air supply header 59 along both sides of the length of the bath is tapped at each burner zone location to provide a four inch secondary air supply header 60. Located at the beginning of the four inch secondary air supply header is an electrically-operated motor-driven valve 67, which regulates the combustion air flow. The motor-driven valve 67 is provided with a two-position switch 68 which indicates LOW-FIRE or HIGH-FIRE conditions. Both the motor-driven valve and the two-position switch have electrical interlocks 79. The four inch secondary air supply header 60 is continued from the motor-driven valve 67 and is tapped with a one inch air line 69 connected to the zone automatic recuperative burner 44. This line is provided with an adjustable shut-off valve 70.
In addition, the automatic recuperative burner 44 is provided with a two inch exhaust stack 71 to atmosphere. Each automatic recuperative burner is furnished with an ignition system. This system comprises an ignition transformer 72, ignition plug 73 and an ultraviolet flame detector 74. Associated with this system are a timer 75, a relay 76 and an indicating light 77 mounted in the ignition section of the burner control panel. Each zone burner has its respective interlock 79. All 79 interlocks are part of the DCS, Distributive Control System. In each burner 44 combustion air and natural gas are ignited and burned within the heat-radiating chamber 46. The residue from the burnt gases (by products of combustion of the natural gas) is exhausted externally to the bath and has no contact with the atmosphere inside the bath. As the burnt gases move through the chamber to the exhaust outlet 52, they preheat the incoming gas and air for a more efficient operation.
One burner control panel for the control of both sides of the bath has three functional sections: main valve train control, the burner ignition control and flame monitoring control. The operational status of all burners is indicated at this panel. If one burner fails to ignite, or fails to continue operating, the operating personnel knows immediately the condition and location of that particular burner and will initiate the corrective procedures. | 4y
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 09/936,069 having a filing date of Jan. 29, 2002, now U.S. Pat. No. 6,878,320, which claims the benefit of PCT International Application Number PCT/GB00/00814 filed Mar. 6, 2000 under 35 U.S.C §371.
BACKGROUND OF THE INVENTION
This invention relates to synthetic auxetic materials, that is, to polymeric materials having a negative Poisson ratio whereby, when stretched in one direction by application of a tensile load, the material expands transversely to that direction. Alternatively, when compressed in one direction, the material contracts transversely to that direction.
Synthetic auxetic materials-have been known since 1987. In the first instance, and as described in U.S. Pat. No. 4,668,557, auxetic materials were prepared as open-celled polymeric foam, negative Poisson ratio properties being obtained as a consequence of mechanical deformation of the foam by compression.
More recently, auxetic materials have been formed as polymer gels, carbon fibre composite laminates, metallic foams, honeycombs and microporous polymers.
Published patent specification WO 91/01210 describes a polymeric material having an auxetic microstructure of fibrils interconnected at nodes. As described, this material is obtained by a process which comprises compacting polymer particles at elevated temperatures and pressures and then deforming the compacted polymer by draw-assisted extrusion through a die to produce a cylindrical rod of auxetic material. A typical process may use a compaction stage with a specially designed processing rig heated to 110-125° C. with a blank die inserted. Polymer powder is added into a barrel of the rig and is allowed to come to temperature for between 3-10 minutes before compaction pressure is applied with a ram at a rate of up to 140 mm/min. The pressure is held at 0.04 GPa for 10-20 minutes and the resulting rod of compacted material is then removed from the barrel of the processing rig and allowed to air cool. The processing rig is then fitted with an extrusion die in place of the blank die and heated up to 160° C. The compacted rod is reinserted into the barrel and sintered at 160° C. for 20 minutes. It is then immediately extruded at a rate of 500 mm/min at 160° C. through a conical die of geometry entry diameter 15 mm, exit diameter 7-7.5 mm, cone semi-angle 30° and capillary length 3.4 mm.
The material obtained from this typical process has auxetic properties derived from the microstructure of the material, namely fibrils interconnected at nodes capable of transverse expansion and increased porosity when the material is stretched.
Auxetic materials are of interest as a consequence of predicted enhancement of mechanical properties such as plane strain fracture toughness and shear modulus. This enhancement has been demonstrated in practice in tests in terms of indentation resistance and ultrasound attenuation with blocks of auxetic microporous ultra high molecular weight polyethylene.
Enhancements in hardness of up to three times at low loads, and very large enhancements (again up to three times) in the attenuation coefficient (i.e. how much of an ultrasound signal is absorbed) are exhibited as between the auxetic material and conventional polyethylene.
Known auxetic materials have been made in the form of bodies with relatively low aspect ratios, and in the case of auxetic microporous polymers these have been made from powder using a three stage process involving compaction, sintering and ram extrusion through a conical die as described above.
Hitherto therefore auxetic materials have not successfully been made in the form of fibres (i.e. with high aspect ratios), despite the interest in such materials. Typically a fibre is an elongate body having a length at least 100 times its diameter.
An object of the present invention is to provide a viable process for the production of auxetic materials in fibre form.
According to one aspect of the invention therefore there is provided an auxetic polymeric material which is of filamentary or fibrous form.
According to a further aspect of the invention therefore there is provided a method of forming an auxetic material comprising cohering and extruding heated thermoformable particulate polymeric material, wherein cohesion and extrusion is effected with spinning to produce filamentary material having auxetic properties.
With this arrangement, surprisingly the use of spinning with cohesion and extrusion provides an effective means of producing auxetic material in filamentary form. It has been found that this process can provide an auxetic microstructure of fibrils and nodes, as with the above mentioned prior art process, but without requiring the separate compaction and sintering stages of the prior art.
SUMMARY OF THE INVENTION
Most preferably the process of the invention is performed without, or substantially without, any separate compaction or sintering stages, compaction or rather cohesion and heating being effected solely as part of extrusion in the spinning process. Preferably also there is no (or substantially no) separate post-extrusion draw stage, finalisation of mechanical treatment being effected wholly or substantially wholly during extrusion rather than subsequently thereto.
The spinning process is preferably performed at a temperature which is high enough to give rise to cohesion of polymer particles sufficient to permit production of filaments, but without causing actual melting and complete coalescence of the particles into a liquid form. This temperature range is usually defined by reference to a typical DSC (Differential Scanning Calorimetry) diffusion endotherm and would fall on the low temperature side of that endotherm.
It is believed that for a fibre to be auxetic its maximum melting temperature and its DSC-derived % crystallinity should be as close as possible to those of the powder from which it has been derived. Thus, it is desirable that the auxetic fibres should comprise powder particles which have been sintered together at a temperature low enough to allow some degree of surface melting yet not high enough to enable bulk melting and hence reduction in crystallinity.
The particles are preferably small sized rough surfaced particles, particularly irregularly shaped and sized particles although varying within a defined size range, say up to 300 μm diameter±10%.
The process may be performed using standard melt extrusion apparatus having an extruder plate (spinneret) with say 40 holes each of 0.55 mm diameter.
The apparatus may have three zones, a barrel zone, an adapter zone and a die zone which are capable of independent temperature control. The barrel zone may itself have three zones (a feed, compression and metering zone) which may be capable of independent temperature control. However, a common temperature maybe employed throughout.
Preferably screw extrusion rather than ram extrusion is used, operating at say 10 rpm.
Appropriate devices may be used for collecting and cooling produced filaments, preferably without applying any appreciable drawing traction thereto. Cooling may be achieved by air cooling, and/or passing the filaments around a cooling roller, or otherwise. Extruded hot filaments may run between a cooling roller and a nip roller, and an air knife may be provided at an appropriate height say 5 mm above the filaments. Further rollers may be provided for guiding the cooled filaments e.g. to a vertical drop and collection point. The rollers may be driven at a relatively low speed, say around 5 meters per minute, to avoid application of significant traction force.
The process may be applied to polypropylene in which case the temperature used may be say 159° C. Other polymeric materials, such as nylon or other polyolefin or polyamide materials may be used particularly polyethylene such as ultra high molecular weight polyethylene. The polymeric material may be mixed with or incorporate any other suitable materials such as fillers, other polymers, etc.
The process may be applied to the production of continuous monofilaments, or short filaments or fibres, and these may be twisted or otherwise combined to give multi-filament or fibrous yarns.
These filamentary or fibrous materials may be formed into textile structures such as woven, knitted or felted fabrics alone or in combination with any other suitable materials.
Filaments or fibres made in accordance with the invention maybe used as reinforcements in composite materials to impart enhanced energy absorption properties and fibre pullout resistance.
Textile structures incorporating or made from filaments or fibres made in accordance with the invention may be used in protective clothing where enhanced indentation properties and low velocity impact resistance are advantageous. Such textile structures may also be used in healthcare. There are also other applications where the material of the invention can be used advantageously.
The invention therefore also provides an auxetic material of filamentary or fibrous form, preferably formed by the process described above, and textile structures made with such auxetic material.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described further by way of example only and with reference to the accompanying drawings in which:
FIG. 1 is a diagrammatic representation of one form of apparatus used in performing the process of the invention; and
FIG. 2 is a diagrammatic representation of the structure of a fibre formed by the process of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows conventional melt extrusion apparatus used in performing the process of the invention, by way of example.
The apparatus has a powder hopper 1 leading to a barrel 2 containing an Archimedean feed screw 3 . The extruder barrel 2 has three zones feed, compression and metering zones 4 , 5 , 6 . The screw 3 has a 3:1 compression ratio, a 1 inch (2.54 cm) diameter and a length-to-diameter ratio of 24:1.
The barrel 2 is connected via a diameter-reducing adapter section 7 to a die 8 comprising a 40-hole spinneret, the holes being of 0.55 mm diameter.
In front of the die there is a cooling roller 9 with a pinch roller 10 and an air knife 11 , and subsequent guide rollers 12 - 14 , a guide rail 15 and a wind-up roller 16 .
A heater is provided (not shown) for heating the barrel 2 at the three separate zones 4 , 5 , 6 along its length, and also at adapter 7 and die 8 .
The heating arrangement permits different temperatures to be maintained for each of these and conventionally this would be in an increasing manner from zone one 4 to zone three 6 .
In use, for polypropylene powder, zone temperature differences might typically be from 10-20° C. In accordance with an example of the present invention a temperature of 159° C. is maintained throughout the three zones 4 - 6 of the barrel 2 , adapter 7 , and die 8 , and polypropylene powder is fed from the hopper 1 to the barrel 2 .
The polypropylene powder in this example has a particle diameter <300 μm, the diameters of individual particles varying within a range of ±10% of a medium diameter. All particles have irregular shapes and rough surfaces.
The polymer used is Coathylene PB 0580, as produced by Plast-Labor S.A., CH-1630 Bulle, Switzerland.
The screw 3 is driven at a controlled relatively slow rate of 10 rpm (corresponding to a throughput of 3.6 gms per minute) and this causes the powder to be advanced along the zones 4 - 6 of the barrel 2 to the adapter 7 and the die 8 . This speed, is selected in relation to other parameters, namely the powder morphology, the temperature, the length of the barrel 2 and adapter 7 , and the cross-sectional characteristics of the barrel 2 , adapter 7 and holes of the die 8 . The powder particles are thereby caused to cohere together and flow through the die holes.
The screw speed is selected to be as slow as possible, and the temperature is as low as possible, whilst achieving smooth fibre characteristics.
The temperature is below the melting point of the polymer so that the particles cohere to form a continuous, fluent body without losing their integrity. Thus, although the apparatus is derived from conventional melt extrusion apparatus, the process involves ‘melt’ or flow spinning, but without melt extrusion occurring.
In particular, and as discussed further below, the powder particles are sintered together at a temperature low enough to allow some degree of surface melting but not high enough to give bulk melting.
The material flows through the die 8 and is taken up by the pinch rollers 9 , 10 without application of any appreciable traction. The material is therefore spun or extruded but not significantly drawn.
The ‘molten’ filaments leaving the die 8 are picked up with a metal rod and draped around the cooling roller 9 prior to engagement of the pinch roller 10 . The pinch roller 10 is then engaged and the air knife moved in position at a setting of 5 mm above the path of the filaments.
From the pinch rollers 9 , 10 , the filaments are taken down from the cooling roller 10 and are passed under roller 12 , up and over roller 13 and then straight across to roller 14 . The filaments are then fed vertically downwards and slid over the guide rail 15 to the wind-up roller 16 .
In this example the rollers 9 , 10 , 12 - 14 , 16 are driven to run at a slow speed of 2 meters per minute to achieve guide of the filaments without applying any appreciable drawing or traction forces. However, at higher barrel extrusion speeds, proportionally higher roller speeds would enable the same fibre characteristics to be achieved. Other rollers such as would be used with apparatus of this kind where drawing is required are not used here.
As a consequence of the above described procedure the filamentary material produced from the die 5 has a micro-structure of fibrils 17 linked by nodes 18 , as shown in FIG. 2 , which gives rise to auxetic properties.
This microstructure is known to provide auxetic properties but has hitherto been obtained by compaction and sintering of the polymer powder, which may be followed by draw extrusion of a relatively large diameter cylindrical rod (say up to 10 or 15 mm). It has been found, surprisingly, that the auxetic microstructure can be obtained with the above described ‘melt’ spinning process without use of separate compacting and sintering stages or paying careful attention to die geometry.
The following table, Table 1, gives detailed parameters for the above described example of the invention, in the column identified Batch M. These parameters are compared with parameters of two other batches, Batch B and Batch H using the same polypropylene powder. Also, characteristic parameters of a sample of raw powder are shown.
Characteristic
Extrusion process
parameters
Batch
PP
parameters
(DSC)
Batch B
Batch H
M
Powder
Temp Screw
173
163
155
Feed Zone (4) -
(° C.)
Temp Screw
185
166
159
Compression
Zone (5) - (° C.)
Temp Screw
205
168
159
Metering Zone
(6) - (° C.)
Temp Adaptor
212
165
158
Zone (7) - (° C.)
Temp Die Zone
210
168
158
(8) - (° C.)
RPM
25
30
10
MPM
5
6
2
T onset - (° C.)
151
155
156
149
T max - (° C.)
165
166
165
165
%
32.3
24.8
45.5
47.8
crystallinity
As can be seen from the table, the batch of raw powder examined starts to melt at 149° C. and melts completely at 165° C., and the % crystallinity of the powder is 47.8%. Parameters were derived using Differential Scanning Calorimetry conducted on a Polymer Labs PL DSC under flowing nitrogen at a heating rate of 10° C./min from 30-200° C. Batch M has somewhat similar characteristic parameters to the raw powder, particularly the crystallinity percentage.
Micrographic analysis of Batch M fibres showed that they had auxetic properties. That is, the fibres showed a structure of fibrils attached to modules. Also, extension of the fibres caused these to expand laterally.
Batch B and Batch H were processed at higher temperatures and higher throughputs. As shown in the table this resulted in a much reduced crystallinity percentage. Micrographic analysis did not reveal any significant auxetic properties.
This demonstrates that, to attain auxetic properties, it is desirable for the powder particles to be sintered together at a temperature low enough to allow some degree of surface melting yet not high enough to enable bulk melting whereby the fibres remain as close as possible to the raw powder particularly with regard to the DSC-derived % crystallinity.
The resulting filamentary auxetic material can be used as reinforcing fibres, or in textile structures, and has advantageous properties suited to a range of applications.
Some possible applications can be identified as follows.
Auxetic fibres can be used as fibre reinforcements in composite materials e.g. polyolefin auxetic fibres in a polyolefin matrix. The auxetic fibres improve resistance to fibre pull out and fibre fracture toughness, and give enhanced energy absorption properties. Sonic, ultrasonic and impact energy can be absorbed enabling superior composites to be made for sound insulation of walls of buildings, body parts for submarines or other vehicles, etc, bumpers for cars, etc. Auxetic materials also respond to impact to give local densification thereby giving enhanced indentation resilience.
Auxetic fibres can be used alone or in combination with other materials for personal protective clothing or equipment as a consequence of the superior energy absorption and impact resistance properties. Crash helmets and body armour (e.g. bullet proof vests) are examples of applications.
For such an application it may be desirable to make the protective material in the form of an auxetic macrostructure made from auxetic fibres (i.e. a hierarchical auxetic material). This would enable a single-component protective material to perform the combined energy absorption and indentation resistance roles, rather than having separate layers to perform each of these tasks in a dual-component material.
These properties should also lead to enhanced sports protective clothing, e.g. shin pads, knee pads, batting gloves etc. The possibility exists of producing protective clothing made from auxetic fibres which have equivalent protective performance to those made from non-auxetic fibres but which are lighter and/or thinner due to the benefits associated with the auxetic property.
Auxetic materials have pore size/shape and permeability variations leading to superior filtration/separation performance in several ways when compared to non-auxetic materials. Application of an applied tensile load on a non-auxetic porous material causes the pores to elongate in the direction of the applied load, which would tend to increase the filter porosity. However, the positive Poisson's ratio of non-auxetic materials causes the pores to contract in the transverse direction, thus reducing the overall porosity in competition with the increase in porosity due to longitudinal pore extension. For an auxetic porous material, on the other hand, the pores extend in both the loading and transverse directions, leading to enhanced porosity variations when compared with the non-auxetic equivalent. Benefits for auxetic filter materials, therefore, include release of entrapped particulates (leading to potential for cleanable filters and filters/membranes where a controlled release of a dose of particles/cells/molecules of a specific size/shape are required, e.g. drug-release materials) and self-regulating filters to compensate for pressure build-up due to filter fouling.
Non-auxetic microporous polypropylene fibres have been proposed for use in cloth filters. Also, non-auxetic microporous fibres, possibly hollow, are themselves used as separation materials in which a two-phase mixture (solid and liquid, for example) is passed down the middle of the fibre, with one phase then passing through the walls of the fibre whilst the other continues to pass down the middle. Hollow polypropylene fibres are employed in, for example, mechanical lung applications in which carbon dioxide is removed from the blood of the patient, and fresh oxygen is supplied to the patient. An auxetic equivalent should have superior performance in terms of selectivity and cleanability in these applications.
Polypropylene fibres are employed in rope or cord and fishnet applications due to their high strength and low weight (i.e. floatation) properties. In addition to the usual methods of strengthening ropes (due to twisting mechanisms between fibres etc) the auxetic effect can further enhance the strength properties of ropes and fishnets.
In the case of two adjacent non-auxetic fibres, application of tension of the fibres causes them to elongate in the direction of tension and to contract radially due to the positive Poisson's ratio. Hence (neglecting twist and friction effects etc.) extension of the fibres is simply governed by the fibre Young's modulus. For two adjacent auxetic fibres, however, the elongation in the direction of applied tension is accompanied by a concomitant increase in radial expansion due to the negative Poisson's ratio. For two fibres in contact this causes radial compression between the fibres which is, therefore, converted into a longitudinal contraction (due to the negative Poisson's ratio) in direct competition to the extension due to the applied tensile load. Hence, in this case the overall longitudinal extension of the fibres is lower than that which would be expected from the fibre Young's modulus as a direct consequence of the auxetic effect. In other words, to a first approximation the extension of two or more non-auxetic fibres in radial contact will be equal to that of a single fibre of equal Young's modulus in isolation and subject to the same applied stress, whereas the extension of two or more auxetic fibres in radial contact will be less than-that of a single fibre of equal Young's modulus in isolation. Hence, a rope or fishnet made from auxetic fibres will have enhanced strength properties.
In addition to the strength enhancements, auxetic fibres also exhibit improved wear resistance due to having enhanced indentation properties. This leads to ropes and fishnets having enhanced abrasion properties to counteract the effects of ingress of, for example, sand grains during use. Improved wear resistance should also be useful in other fibre applications such as upholstery fabrics etc.
Naturally-occurring auxetic biomaterials are known, for example cow teat skin, cat skin and certain forms of bone. In developing synthetic replacement biomaterials it is desirable to consider auxetic functionality in order to ensure an adequate match in the mechanical properties of the real and synthetic materials. Currently, fibrous biomedical materials include cartilage, surgical implants and suture anchors or muscle/ligament anchors, where the additional benefit of a microporous structure should promote bone in-growth. The use of auxetic fibres leads to benefits by ensuring an adequate match in mechanical properties, improved strength and wear resistance for load bearing components (e.g. cartilage), and improved ‘anchoring’ properties.
Auxetic fibres can be used in bandages and pressure pads in wound care. Important properties in these applications may include that the bandage maintains pressure on the wound to prevent swelling of the wound, and enables the wound to breathe through the macropores of the bandage structure whilst also preventing infection of the wound. Ideally the bandage may also enable wound-healing to occur by application of an appropriate wound-healing agent.
A tubular bandage or pad or strip formed from auxetic fibres can be applied around a limb. Auxetic fibres would tend to act to maintain the breathability and pressure applied by an auxetic bandage on the wound despite any swelling of the wound.
Furthermore, if the auxetic fibres are ‘loaded’ with a wound-healing component (i.e. the wound-healing component particles are initially entrapped within the auxetic fibre microstructure) then the extension in length and thickness of the fibres due to wound swelling would open up the fibre micropores, thus enabling release of the wound-healing component to counteract the initial swelling.
Other miscellaneous applications are: fire-retardant (FR) fibres—due to incorporating FR component in pores of fibre by extending fibre during processing and then entrapping FR component by closing up pores due to release of extension after processing;
drug-delivery fibrous materials—similar to FR fibres where drug molecules/particulates are entrapped within fibres and subsequently released by extending fibres to open up pores;
other fibres which need to contain an additional component within the pores (e.g. dye molecules for dyeability);
composite fibres—in which one or more components are auxetic fibres (e.g. winding a dyeable fibre around an auxetic fibre in order to produce a fibre having benefits due to auxetic effect and also dyeability property);
fibrous seals—to exploit advantages due to auxetic property in seal and gasket applications.
It is of course to be understood that the invention is not intended to be restricted to the details of the above embodiment which are described by way of example only. | 4y
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CROSS REFERENCE TO RELATED APPLICATIONS
The instant application is related to and claims priority from United States Provisional Application Ser. No. 60/024,319 filed Aug. 22, 1996.
BACKGROUND OF THE INVENTION
Solid-state chemists, following nature's geologic examples, have transformed common silicate, aluminate, and phosphate building-blocks into zeo-type materials with elaborate structural frameworks. These porous materials provide molecular sieve and catalysis technology vital to countless applications in diverse industries. There is an ongoing need for new materials having such properties.
SUMMARY OF THE INVENTION
Disclosed herein is a novel class of halide-based framework solids based on a Zn n Cl 2n parentage, as zeo-types are related to Si n O 2n . These materials, referred to as halo zeo-type materials, constructed from Lewis acidic and redox active tetrahedral building blocks, should augment the size and shape selectivity characteristics of zeo-type frameworks.
A first aspect of the present invention is the compound CZX-1. CZX-1 has the formula NH(CH 3 ) 3 !CuZn 5 Cl 12 , and has the crystal structure given in Table 1 below.
A second aspect of the present invention is the compound CZX-2. CZX-2 has the formula NH 2 (CH 2 CH 3 ) 2 !CuZn 5 Cl 12 , and has the crystal structure given in Table 2 below.
A third aspect of the present invention is the compound CZX-3. CZX-3 has the formula H 2 N(CH 3 ) 2 ! n Cu n Zn 6-n Cl 12 !, wherein n may be 1 or 2. CZX-3 has the crystal structure given in Table 3.
A fourth aspect of the present invention is the compound CZX-4. CZX-4 has the formula A! n Cu 2 Zn 2 Cl 7 !, wherein A may be H 3 NCH 3 + or Rb + . CZX-4 has the crystal structure given in Table 4.
The foregoing and other objects and aspects of the present invention are explained in detail in the specification set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a-1c describe representation of the skeletal frameworks of CZX-1 (FIG. 1a), CZX-2 and CZX-3 (FIG. 1b), and CZX-4 (FIG. 1c).
DETAILED DESCRIPTION OF THE INVENTION
Compounds are disclosed which have the general formula Cu n Zn m-n Cl 2m ! n- . Various values may be assigned to "n" and "m" including, but not limited to, "n" equal to 1 or 2 and "m" equal to a number between 4 and 6. The compounds of the present invention can be readily synthesized by those skilled in the art. In overview, single crystals of CZX-1, CZX-2, CZX-3, and CZX-4 suitable for X-ray structural determinations, can be grown from superheated benzene solutions (160° C. under autogenous pressure) of CuCl, ZnCl 2 and (1) HNMe 3 Cl for CZX-1; where "Me" means methyl, (2) H 2 NEt 2 Cl for CZX-2; where "Et" means ethyl, (3) H 2 N(Me) 2 !Cl for CZX-3, and (4)H 3 NMeCl or RbCl for CZX-4, respectively. In a dry box with a nitrogen atmosphere, the chloride salt of the templating cation, CuCl, ZnCl and benzene (C 6 H 6 ) in an appropriate mole ratio (a mole ratio of 1:1:5:65 for CZX-2 for example) are placed in a thick walled fused silica tube reaction vessel. The reaction vessel is then sealed under vacuum and heated at 160° C. for four hours and then slowly cooled. Samples are also readily prepared from melts, ≦200° C., of the same compositions, however, microcrystalline products were obtained. Though it is not possible to directly determine the Cu/Zn ratio (or distribution in the framework) by X-ray diffraction, these colorless, diamagnetic materials require that one templating cation (HNMe 3 + , H 2 NEt 2 + , H 2 NMe + , or Rb + must charge balance each Cu I in the framework. The refinement of the templating cation occupancies in the crystal structure is consistent with EDS measurement of the Cu/Zu ratio of 1:5.
Compounds of the present invention may be used for a variety of purposes. The size and shape of the pores and cavities in these novel metal halide framework materials make them useful as molecular sieves, particularly for gas separations and sensors. The pores and channels of these frameworks also make them useful as hosts for nano-particles such as quantum confined semiconductor particles. The framework characteristics also make them useful for ion exchange and battery applications by combination of the ion mobility and the Cu I /Cu II redox couple.
Compounds of the present invention are also useful for a variety of catalytic applications. These novel materials add size and shape selectivity to known redox catalysis based on the Cu I /Cu II redox couple such as reduction of carbon monoxide or oxidative coupling reactions. In addition, ZnCl 2 has known utility as a Lewis acid and as an alkyl transfer agent. Various forms of CuCl/O 2 are valuable oxidation catalysts. As such oxidation catalysts, CZX-1, CZX-2, CZX-3, and CZX-4 have well isolated copper sites in a size and shape selective cavity, like an "inorganic enzyme." This is a reminiscent of copper-containing metalloproteins that reduce dioxygen under ambient conditions.
CZX-1 crystallizes in the I-43m acentric space group, and CZX-2 and CZX-3 crystallize in the acentric space groups and I2 1 2 1 2 1 , the former is both polar and acentric. CZX-4 crystallizes in the monoclinic space group Pn with H 2 NMe + and the orthorhombic space group P2 1 nm with Rb + . These crystal symmetries and the polarizability of the metal-chlorine bonds make these materials useful for piezoelectricity and second harmonic generation (e.g., as pieazoelectric crystals and for nonlinear optical devices such as frequency doublers). In addition, these materials are colorless and optically transparent, making them useful for the fabrication of optical components.
The invention also encompasses colloidal suspensions which may comprise the compounds described herein. The colloidal suspensions may be prepared using known techniques. For example, suspensions with particle sizes of about 100 nm (measured by optical microscopy) may be prepared by adding an alcohol (e.g., methanol) or water. Preferably, from about 20 to about 40 molar equivalents of alcohol or water are combined with one molar equivalent of compound which is employed. More preferably, about 40 molar equivalents of methanol are employed for one molar equivalent of compound. The resulting colloidal suspension may remain suspended for days. Concentrating the colloidal suspension using suitable apparatus (e.g., a nitrogen filled dry-box) may yield a homogeneous paste with the appearance and consistency of a typical commercial glue. The colloidal suspensions are advantageous in that they are capable of providing an increased surface area which may allow for greater catalytic activity when the compounds are employed in processes.
The present invention is explained in greater detail in the following non-limiting examples. In these examples, "Me" means methyl, "Et" means ethyl, "EDS" means energy dispersive spectroscopy, and temperatures are given in degrees centigrade.
EXAMPLE 1
Synthesis of CZX-1, CZX-2, CZX-3, and CZX-4
Crystalline compounds of the invention were synthesized from superheated solutions of alkylammonium chloride (or RbCl in the case of one embodiment of CZX-4), CuCl, ZnCl 2 , and benzene used in various molar ratios. The molar ratios generally varied from 1:1:5:45 to 1:1:5:65. When synthesizing the compounds, amounts of the reactants are varied so as to be consistent with the chemical formulae of the resulting compounds. With respect to CZX-1, 25 mg of CuCl, 170 mg of ZnCl 2 , and 24 mg of HNMe 3 Cl were added to a thick walled fused silica tube. Using standard Schlenk techniques, 1.0 ml of benzene was added to this reaction vessel. The reaction mixture was frozen in liquid nitrogen and sealed using a torch such that the reaction tube was filled to 25 percent. Hardened solids from which colorless single crystals could be cleaved were prepared by cooling the benzene solutions from 160° C. to 60° C. at 0.01 degree/min. The procedure was repeated using appropriate reactants for CZX-2 and CZX-3. The elemental analyses for the materials were as follows: CZX-1 (calculated for C 3 H 10 Cl 12 CuNZn 5 ): C, 4.1; H, 1.2; N, 1.6. Found C, 4.3: H, 1.3; N, 1.6. CZX-2 (calculated for C 4 H 12 Cl 12 CuNZn 5 ): C, 5.4; H, 1.4; N, 1.6. Found C, 5.3: H, 1.5; N, 1.4. CZX-3 (calculated for C 4 H 16 Cl 12 Cu 2 N 2 Zn 4 ): C, 5.3; H, 1.8; N, 3.1. Found C, 5.3: H, 2.0; N, 3.0.
EXAMPLE 2
Crystal Structure of CZX-1
CZX-1 crystallizes in the cubic, acentric space group I-43m with a=10.5887(3) Å. The stoichiometry required by the crystal structure of CZX-1 was confirmed by EDS. The ability to prepare zeo-type analogues with mixed metal halides is readily demonstrated by CZX-1 which adopts the sodalite structure. Copper and zinc atoms reside on a single 4 bar crystallographic site, and are linked through two-coordinate chloride ligands. Each sodalite cage exhibits a free volume of 158 Å 3 , and is filled by a disordered trimethylammonium cation. The comparison of the calculated density of CZX-1 (2.45 g/cm 3 ) and that of orthorhombic-ZnCl 2 (3.00 g/cm 3 ) illustrates the extent to which this halo zeo-type is an open framework. Bond lengths and angles are given in Table 1 below.
TABLE 1______________________________________Bond Lengths and Angles for CZX-1Bond Lengths (Å) Bond Angles (E)______________________________________T-Cl 2.285 (2) × 4 Cl-T-Cl 107.82 (3) × 4 112.83 (3) × 2______________________________________ T = tetrahedral metal site, occupied by Cu and Zn.
EXAMPLE 3
Crystal Structure of CZX-2
CZX-2 crystallizes in the acentric space group I2 1 2 1 2 1 with a=9.6848(5) Å, b=9.5473(4) Å, and c=14.0003(9) Å. The stoichiometry determined by the crystal structure was confirmed by EDS. CZX-2 displays a novel zeo-type framework constructed with 3-ring secondary building units (SBU). These SBUs link to form circular channels parallel to b with 11-ring apertures. Additional 8-ring channels parallel to the body diagonal (111); link the pores in a three-dimensional network. 4-ring and 6-ring channels are observed parallel to a. The free volume of the channels is 382 Å 3 /unit cell (Z=2), and the calculated density of the structure is 2.28 g/cm 3 . Bond lengths and angles are given in Table 2 below.
TABLE 2______________________________________Bond Lengths and Angles for CZX-2.Bond Lengths (Å) Bond Angles (E)______________________________________T1-C11 2.288 (2) × 2 C11-T1-C11 114.62 (9)T1-C12 2.315 (2) × 2 C11-T1-C12 114.24 (7)T2-C11 2.273 (2) 103.82 (6)T2-C12 2.275 (2) C12-T1-C12 106.08 (8)T2-C13 2.291 (1) C11-T2-C13 105.96 (7) C11-T2-C14 108.36 (5) C12-T2-C13 108.27 (5) C12-T2-C14 108.93 (7) C13-T2-C14 111.05 (6)______________________________________ T = tetrahedral metal site, occupied by Cu and Zu. The distribution of Cu and Zn over the two T sites in CZX2 has not been conclusively determined.
EXAMPLE 4
Crystal Structure of CZX-3
CZX-3 crystallizes in the acentric space group I2 1 2 1 2 1 with a=9.5677(16) Å, b=9.4554(12) Å, and c=13.6435(16) Å. The stoichiometry required by the crystal structure of CZX-3 was confirmed by EDS. CZX-3 displays a novel zeo-type framework constructed with 3-ring secondary building units (SBU). These SBUs link to form circular channels parallel to b with 11-ring apertures. Additional 8-ring channels parallel to the body diagonal (111); link the pores in a three-dimensional network. 4-ring and 6-ring channels are observed parallel to a. The calculated density of the structure is 2.439 g/cm 3 . Bond lengths and angles are given in Table 3 below.
TABLE 3______________________________________Bond Lengths and Angles for CZX-3.Bond Lengths (Å) Bond Angles (°)______________________________________T1-C13 2.279 (3) × 2 C13-T1-C13 114.74 (16)T1-C14 2.284 (4) × 2 C13-T1-C14 114.80 (12)T2-C13 2.314 (4) 102.40 (12)T2-C14 2.285 (4) C14-T1-C14 107.94 (15)T2-C15 2.293 (3) C13-T2-C14 113.16 (14)T2-C16 2.298 (3) C13-T2-C15 103.38 (14) C13-T2-C16 107.76 (10) C14-T2-C15 107.84 (11) C14-T2-C16 111.35 (13) C15-T2-C16 113.18 (11)______________________________________
EXAMPLE 5
Synthesis of CZX-4
CZX-4 crystallizes in the monoclinic space group Pn, with a=6.3098(8) Å, b=6.6339(8) Å, and c=15.569(2) Å, wherein A=H 3 NMe + and β=91.11(1)°. The compound exhibits a polar axis. CZX-4 may also crystallize in the orthorhombic space group P2 1 nm, with a=6.06 Å, b=6.52 A, and c=15.39 A, wherein A=Rb + . Both compounds crystallize in acentric space groups and the later has a polar axis.
It is believed that the CZX-4 framework structure is not a direct zeo-type analog, but is isostructural with BaAl 4 S 7 . The CZX-4 structure may demonstrate that similar open framework structures may be constructed by small variations from the prescribed Cu n Zn m-n Cl 2m ! n- formulation. In this structure, the templating cations sit in cages that are surrounded by 12 nearest neighbor chloride anions. These cages are connected by six ring windows forming channels along the a and b directions which are believed to allow for the possibility of cation mobility and ion exchange. The calculated density of the structure is 2.74 g/cm 3 . CZX-4 may be synthesized by procedures similar to those employed in synthesizing CZX-1 and CZX-2. Bond lengths and angles are given in Table 4 below.
TABLE 4______________________________________Bond lengths and angles for CZX-4Bond Lengths (Å) Bond Angles (°)______________________________________T1-C11 2.402 (10) C1-T-C1 102.5 (3) to Range: 121.4 (3)T1-C12 2.439 (7)T1-C13 2.300 (8)T1-C15 2.283 (8)T2-C11 2.484 (7)T2-C12 2.413 (11)T2-C14 2.290 (10)T2-C16 2.296 (9)T3-C11 2.279 (9)T3-C13 2.262 (11)T3-C16 2.249 (7)T3-C17 2.306 (8)T4-C12 2.285 (8)T4-C14 2.257 (11)T4-C15 2.253 (7)T4-C17 2.332 (9)______________________________________
EXAMPLE 4
Methanol Absorption by Colloidal Suspensions
The absorption of methanol by colloidal suspensions employing compounds of the present invention was investigated. Methanol was passed over compounds CZX-1, CZX-2, and CZX-3 as well as liquid ZnCl 2 and solid CuCl, in an appropriate apparatus at 30° C. in a nitrogen atmosphere. For the compound CZX-3, the molar ratio of zinc to copper was 5:1 in one sample (n=1), 4:2 in the second sample (n=2). The compounds were then purged with nitrogen and the amount of methanol desorbed in the nitrogen purge was determined. The equivalents of methanol absorbed and remaining after a dry nitrogen purge were determined by gravimetric analysis and are set forth in Table 5 below.
As shown, the solid CuCl was not capable of incorporating any of the methanol into its structure, whereas ZnCl2 adsorbed methanol forming a liquid solvate. By contrast, the CZX materials both adsorbed methanol and formed colloidal suspensions. The compounds of the invention demonstrate the capability of incorporating molecules into their framework. Accordingly, the compounds of the invention may display sieve-like functions in that they are able to discriminate which type of materials may be adsorbed by the compound structures.
In general, while some of the adsorbed methanol may be necessary for stabilization of the colloid, additional methanol is able to be absorbed within the structures of CZX-2 and CZX-3 (n=1). In this instance, the framework of these materials is constructed with only half the templating sites occupied. The remaining sites can be occupied with additional solvent molecules such that these materials can adsorb 1.8 moles of methanol per framework-formula-unit more than the corresponding fully stuffed CZX-3 (n=2) framework.
TABLE 5______________________________________Methanol sorption/desorption of halo zeo-type compounds MeOH dry N.sub.2 Wetted N.sub.2 purge______________________________________ZnCl.sub.2 3.5 0.9CuCl 0.0 0.0CZX-1 2.3 0.5CZX-2 2.5 0.8CZX-3 (1 Cu:5 Zn) 2.4 0.8CZX-3 (2 Cu:4 Zn) 1.6 0.5______________________________________
The foregoing examples are illustrative of the present invention, and are not to be construed as limiting thereof. The invention is defined by the following claims, with equivalents of the claims to be included therein. | 4y
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of Provisional Application No. 60/781,453 filed Mar. 10, 2006, entitled “An Articulating Handle for Space-Saving Cookware and Methods for Doing the Same”, which is incorporated in its entirety by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to an articulating handle for space-saving cookware and, more particularly, to an articulated handle for cookware that is configured to save space by rotating between and locking into multiple positions, and methods for using the same.
2. Description of Related Art
Consumers have been frustrated for many years by the inability to neatly and efficiently store cookware, e.g., a variety of sizes of pans, pots, etc., in cabinets, particularly a variety of sized pieces of cookware. Conventional cookware generally includes a handle that is fixed to a side of the cookware and protrudes outwardly from the side. This protruding handle generally occupies shelf space within the cabinet, preventing another piece of cookware from being positioned in a side-to-side manner adjacent the first piece of cookware. Such a conventional handle design creates wasted space within the cabinet.
Moreover, although conventional cookware pieces may nest within one another, there has always been a problem with conventional cookware nesting in a level stacked arrangement due to the attached handles. Inevitably, the end result of any effort to nest cookware pieces (e.g., pans with handles) for storage is an unstable, un-level arrangement that does not make the best use of available storage space due to the acute angle of the nested cookware. This acute angle is caused by the handle of an inner, smaller piece of cookware resting on a sidewall of an outer, larger piece of cookware.
Generally, cookware designed to address this problem includes either collapsible or removable handles. However, these types of handles create separate problems of their own, such as adding complexity to the cookware's design and manufacture as well as demands on the consumer. In addition, the removable handles also require the consumers to remove and store the handles separately, which adds the potential risk of the consumer misplacing the handles. Thus, there is still a need for an improved handle for cookware.
SUMMARY OF THE INVENTION
The present invention solves the problems heretofore encountered in the prior art by providing an articulated handle for cookware wherein the cookware may be nested in a level arrangement, thus saving storage space. The articulated handle of the present invention does not require removal of the handle prior to storing the cookware due to the inventive handle assembly which permits locking and unlocking the handle assembly for vertical positioning the handle when storing.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the invention, embodiments of the invention will be better understood from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of an exemplary embodiment of an articulating handle for cookware according to the present invention;
FIG. 2 is an exploded perspective view of the handle illustrated in FIG. 1 ;
FIG. 3 is a side elevational view of the handle illustrated in FIG. 1 in a substantially vertical position;
FIG. 4 is a top plan view of the handle illustrated in FIG. 1 ;
FIG. 5 is a cross-sectional view of the handle illustrated in FIG. 4 ;
FIG. 6 is a cross-sectional view of the handle illustrated in FIG. 4 , wherein the locking lever is in the unlocked position;
FIG. 7 is a top plan view of an exemplary embodiment of a nested arrangement of cookware pieces having articulating handles according to the present invention;
FIG. 8 is a side elevational view of the nested arrangement illustrated in FIG. 7 ; and
FIG. 9 is an exploded view of the nested arrangement illustrated in FIG. 7 .
The embodiments set forth in the drawings are illustrative in nature and not intended to be limiting of the invention which is defined by the claims. Moreover, individual features illustrated in the drawings will be more fully apparent and understood with reference to the following detailed description.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to various embodiments of the invention, examples of which are illustrated in the accompanying drawings, wherein like numerals indicate similar elements throughout the views.
FIGS. 1-6 disclose an exemplary embodiment of a space-saving cookware 10 according to the present invention. Such an embodiment saves space within storage cabinets and permits multiple cookware pieces to be neatly stacked and stored within the cabinets. The exemplary cookware 10 includes a receptacle 20 and an articulating handle assembly 40 . Receptacle 20 may include a sidewall 24 , bottom wall 26 , a reservoir 22 formed by sidewall 24 and bottom wall 26 , and a hinge assembly receiving device 28 connected to the sidewall. Hinge assembly receiving device 28 may be connected to sidewall 24 by any conventional device or method known to one of ordinary skill in the art, including but not limited to a rivet, screw, bolt, welding, brazing, etc. It is understood that receptacle 20 may comprise, but is not limited to, pots, pans, boilers, woks, griddles or any other cookware as known to one of ordinary skill in the art. In addition, receptacle 20 may be fabricated from any conventional materials used in cookware such as metals, metals coated with non-stick material and/or other materials as known to one of ordinary skill in the art.
As shown in FIG. 2 , cookware 10 may include a hinge assembly 30 that is connected to sidewall 24 of receptacle 20 using a fastener 32 that connects hinge assembly 30 to hinge assembly receiving device 28 . It is understood that hinge assembly 30 may be connected to sidewall 24 by any conventional device or method known to one of ordinary skill in the art, including but not limited to a rivet, screw, bolt, welding, brazing, etc. In the exemplary embodiment, fastener 32 is a screw that is threadingly received into hinge assembly receiving device 28 . The exemplary hinge pin shown in FIGS. 2 , 5 and 6 includes two detents 36 and 38 spaced approximately 90 degrees apart from each other along the circumference of hinge pin 34 , permitting handle assembly 40 to be locked into a substantially horizontal position (e.g., FIGS. 1 and 5 ) or a substantially vertical position ( FIG. 3 ), respectively. It is understood that hinge pin 34 may include multiple detents in order to permit handle assembly 40 to lock into multiple positions along the hinge pin.
Handle assembly 40 is configured such that when connected to receptacle 20 via hinge assembly 30 , it may rotate about hinge pin 34 . For example, in the exemplary embodiment, handle assembly 40 rotates about hinge pin 34 between the substantially horizontal position (e.g., FIGS. 1 and 5 ) or the substantially vertical position ( FIG. 3 ). Handle assembly 40 includes a locking lever 42 , a locking cam 44 connected to locking lever 42 , an upper clamp 60 , a lower clamp 70 rotatably connected to upper clamp 60 , a clamp actuator 50 , and a handle grip 80 attached to an underside 66 of upper clamp 60 .
Lower clamp 70 includes a first lower clamp end 72 , a lower clamp hole 74 , and a protrusion 75 . Lower clamp 70 is formed such that a portion of its body substantially confirms to the shape of hinge pin 34 and that protrusion 75 extends inwardly from an inside surface 73 of clamp 70 . Protrusion 75 is configured to engage detents 36 and 38 in order to stop and/or lock handle assembly 40 into the substantially horizontal and vertical positions, respectively.
Upper clamp 60 includes a first upper clamp end 62 and a hollow 64 disposed within upper clamp 60 . At first clamp end 62 , upper clamp 60 is formed to substantially conform to the shape of hinge pin 34 . Upper clamp 60 and lower clamp 70 are rotatably connected to each other at upper and lower first ends 62 and 72 using clamp pin 78 such that they encompass hinge pin 34 in order to rotatably connect handle assembly 40 to receptacle 20 . Clamp actuator 50 , in the exemplary embodiment, includes a first actuator end 54 at one end and a head 52 at an end opposite the first actuator end. Clamp actuator 50 and head 52 may comprise a bolt and head, respectively. It is understood that other devices may be used for clamp actuator 50 and head 52 as known to one of ordinary skill in the art.
Locking lever 42 includes a hinge pin hole 48 disposed near cam 44 . Locking lever 42 is rotatably connected to clamp actuator 50 and upper clamp 60 within hollow 64 using a lever hinge pin 46 that is disposed through pin hole 48 and actuator first end 54 and connects the lever to upper clamp 60 . In addition, clamp actuator 50 is disposed through an aperture (not shown) in upper clamp aperture 60 within hollow 64 and through lower clamp hole 74 such that head 52 engages an outer surface 76 of lower clamp 70 . As such, clamp actuator 50 causes upper clamp 60 and lower clamp 70 to substantially encompass hinge pin 34 .
In operation, when lever 42 is moved to the unlock position as shown in FIG. 6 , cam 44 moves actuator 50 such that head 52 disengages outer surface 76 , permitting the upper and lower clamps to move apart or partially separate. When upper and lower clamps 60 and 70 , respectively, move apart, protrusion 75 disengages detents 36 and/or 38 , which permits handle assembly 40 to rotate about hinge pin 34 . For example, if handle assembly 40 is locked in a substantially horizontal position shown in FIG. 1 , lever 42 may be moved up and away from upper clamp 60 to the unlocked position, and handle assembly 40 may be rotated to the vertical position shown in FIG. 3 . Once in the substantially vertical position, lever 42 may be moved back toward upper clamp 60 into the locked position, wherein the upper and lower clamps close, tighten around, and/or clamp onto hinge pin 34 . This closing of upper and lower clamps 60 and 70 cause protrusion 75 to engage detent 38 , locking the handle assembly in the substantially vertical position. Alternatively, the process may be repeated to cause protrusion 75 to engage detent 36 , locking handle assembly 40 into the substantially horizontal position.
It is understood that hinge assembly 30 , handle assembly 40 and any or all of their components may be fabricated from a variety of conventional materials, including but not limited to metals, plastics, ceramics, composite materials, any combinations thereof, or any other materials as known to one of ordinary skill in the art. In one exemplary embodiment, the upper clamp, lower clamp, and actuator are fabricated from aluminum, the locking lever is fabricated from stainless steel, and the handle grip is fabricated from plastic.
Referring now to FIGS. 7-9 , an exemplary embodiment of a nested arrangement of stacked cookware according to the present invention is shown as 90 . Nested arrangement 90 may include multiple cookware pieces having articulated handles as described herein. The exemplary embodiment includes nine (9) cookware pieces ( 100 , 200 , 300 , 400 , 500 , 600 , 700 , 800 and 900 ), wherein the size, e.g., the diameter of the receptacle, may increase in ascending order. Thus, in the exemplary, cookware piece 100 is the smallest (e.g., smallest diameter), cookware piece 200 is slightly larger in size compared to piece 100 (e.g., larger diameter than cookware piece 100 ) and so on. The nested arrangement is assembled such that each correspondingly smaller cookware piece fits within and is placed within the next correspondingly larger cookware piece. For example, piece 100 is placed within the receptacle of piece 200 , which is placed within the receptacle of piece 300 , which is placed within the receptacle of piece 400 and so on until the nested arrangement includes all nine (9) pieces.
As set forth above, a plurality of the cookware pieces includes articulated handle assemblies (e.g., handle assemblies 102 , 202 , 302 , 402 , 502 , 602 , 702 , 802 and 902 ) that when rotated to the substantially vertical position may fit within the next correspondingly larger cookware piece's receptacle as shown in FIGS. 7 and 8 . Such a configuration reduces the overall height (H) of nested arrangement of cookware pieces 90 but also the length (L) and width (W). The height (H) of the exemplary is approximately 336 mm, the length (L) is approximately 360 mm, and the width is approximately 313 mm. In other words, nested arrangement 90 occupies a volume of space less than 0.04 m 3 , in another exemplary less than or equal to 0.0379 m 3 . The present invention saves shelf space and provides for a user to neatly stack a plurality of cookware pieces having a variety of sizes and shapes.
While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. The presently preferred embodiments described herein are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof. | 4y
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BACKGROUND OF THE INVENTION
The present invention relates to an improved means of removeably attaching postage stamps to backings, such as, sheets of paper or plastic. More particularly, the present invention relates to an improved stamp hinge that may easily and quickly be peeled from the back of a postage stamp, either in used or mint condition, without damaging the stamp by tearing and without leaving a adhesive residue, or deposit, stain, or other mark on the stamp. The present hinge is also easily and quickly removed from stamp album pages or display sheets without damage to, or leaving adhesive residue, stain, or other mark on the pages or display sheets.
For years postage stamp collectors have utilized stamp hinges to attach postage stamps to album or display pages. Typical present day stamp hinges are fabricated from glassine paper having a coating on the contact side of the hinge of water-soluble adhesive. Stamp hinges generally range in size from about 1/4 to about 1/2 inch in width and from about 1/2 to about 3/4 inch in length. Typically the water-soluble adhesive layer is comprised of mixtures of materials such as starch and the vegetable gums, dextrins, and water-soluble gums such as, gum arabic, ghatti, tragacanth, Indian gum and the like. In use the collector, or displayer, dampens the adhesive layer and attaches a portion of the hinge to the back portion, usually the top back portion, of the postage stamp to be mounted. The remainder of the hinge is then bent downward, if not already precreased, and attached to the album page.
The adhesive, or gum, utilized on the backs of postage stamps is also a water-soluble adhesive and is typically comprised of materials similar to that used on hinges. When a hinge is attached to the gum on a mint postage stamp, a mixture of the two water-soluble adhesives occurs. As a result, after drying, the hinge frequently can be removed only with difficulty and risk of damage to the stamp. After removal the gum on the stamp remains disturbed. The value to a stamp collector for "never hinged" mint stamps is substantially higher than for mint stamps showing a hinge mark or stain.
BRIEF DESCRIPTION OF THE INVENTION
The present hinges are pressure-sensitive, that is, the adhesive is permanently tacky at room temperature, and the hinges may be made to adhere to the surfaces to which they are applied by mere contact without the need of more than finger, or slight contact, pressure. The present stamp hinges are manually peelable. The adhesive layer consists of a holding adhesive that leaves no noticeable residue on the adherend surfaces, either the postage stamp or the album or display page, after the hinge has been removed. The present hinges are non-staining and non-damaging to the postage stamp. The present hinges may be manually removed, even from mint stamps, without leaving a detectable hinge mark or causing damage to, or disturbance of, the gum layer on the stamp. The adhesive layer utilized on the present hinges is water-insoluble and does not chemically react with either the postage stamp or the substrate to which the stamp is to be attached.
DETAILED DESCRIPTION OF THE INVENTION
The adhesive materials useful on the present stamp hinges are suitably selected from those commercially available on the market. The useful adhesives are selected to have little or no adhesive build-up, i.e., there is substantially no increase in the peel adhesion value after the hinge has been allowed to dwell on the applied surface over an extended period of time. The useful adhesives leave no detectable adhesive deposit, that is, when the hinge is detached from a surface, no discernable adhesive material material is pulled away from the hinge surface and remains adhered to the surface to which the hinge was applied. The useful adhesives have little or no cold flow, i.e., they have substantially no tendancy to act like a heavy viscous liquid over long periods of time, which otherwise may result in detrimental oozing, migration, and frequently increases in ultimate adhesion. The useful adhesives leave little or no latent stain, that is, stains which do not become noticeable until sometime after removal, usually after the contact surface has been later exposed to sunlight or heat.
The present adhesives are low tack and the hinges have a peel adhesion ranging between about 0.5 and about 3.0 oz./in., and more preferably between about 1.0 and about 1.5 oz./in. Peel adhesion is the force per unit width, expressed in oz./in. that is required to break the bond between the hinge and the surface to which it is applied when the hinge is peeled back at an angle of 180 degrees. Suitable adhesives are those marketed by Minnesota Mining Co. (3M) and utilized on products nos. 653, 654, 655, and 682.
The flexible backing utilized in the present hinges may suitably be paper, for example, glassine, or a high grade nonsulphate paper, or an inert, non-bleeding, plastic film, for example, mylar.
The adhesive material is suitably spread, or layered, on the backing material by any of the methods well known in the art, for example, by knife, roller, coating, or calendering. Typically after the adhesive layer is spread, it is partially dried to produce a pressure-sensitive film, or layer, of the desired thickness and low tack. The hinges are subsequently cut from larger coated sheets by methods which are also well known in the paper art, for example, those methods used in the fabrication of paper tablets and pads.
Although the adhesive layer may suitably cover the entire contact surface of the present stamp hinge, it is preferred that a non-coated, or ungummed, area extend along at least one edge of the hinge to facilitate separation of the hinges one from the other by the user and to enable the present hinges to be manufactured, packaged and stored in a layered arrangement. That is in layered stacks, or blocks. The non-coated edge area permits the user to easily separate and remove the topmost hinge from the stack without disturbing the remainder of the hinges which comprise the stack. The non-gummed area preferably extends along the edge of at least one entire length or one entire width of the hinge. In a further useful embodiment the hinge has a non-gummed area extending across the middle of the hinge to facilitate ease of folding the hinge during the stamp mounting operation. In a further embodiment the adhesive coating on the present hinges is discontinuous, that is, the adhesive surface is comprised of spots, or areas, that are uncoated and spots and areas that are coated.
The attached drawings illustrate several preferred embodiments of the present invention, including the use of various types of useful adhesive arrangements aptly suited to use in the present invention. Like numbers designate like components in each of the separate views.
FIG. 1 is a perspective view illustrating a hinge of the present invention having a non-coated area along one edge.
FIG. 2 is also a perspective view of a hinge of the present invention illustrating a discontinuous adhesive area.
FIGS. 3, 4, and 5 are prespective views of hinges illustrating various adhesive layer configurations.
Looking now at FIG. 1, a stamp hinge, generally designated as 11, typically fabricated of a flexible backing material of a thin sheet of paper or plastic, has low tack, water-insoluble adhesive coating, or layer, 13 on the contact surface thereof. Hinge 11 has a non-coated, or area without adhesive, 15 extending the length of one side thereof. As shown, the non-coated area extends along only one edge, or side of the contact surface of the hinge, however, it will be understood, and illustrated in the additional drawings, that the non-coated area may extend along more than one side, and may extend around the entire periphery of the hinge. The total non-coated area comprises from about 5 to about 95 percent, and more preferably from about 10 to about 35 percent, of the total contact area of the hinge surface. FIG. 2 illustrates a discontinuous adhesive coating layer, 15. As shown the adhesive layer is comprised of strips of adhesive, such as 17. Strips 17 may be arranged parallel to the length, or the width, or angled across the hinge contact surface. FIG. 2 also illustrates a hinge having non-coated edges, 15, along both the length and the width of the hinge.
FIG. 3 illustrates a hinge having a discontinuous adhesive layer comprised of separate smaller areas of adhesive, such as, 19. As shown the smaller areas of adhesive are in the form of dots, however, it will be understood that the areas may be in the form of circles, crosses, combinations thereof or in a random arrangement. FIG. 3 also illustrates a hinge wherein a non-coated area, 21, extends across the center of the hinge to facilitate folding of the hinge and to insure that there is no exposed adhesive area along the point of the fold when the hinge is used. For example, portion 23 may be attached to the back of a postage stamp and portion 25 attached to the album page or display sheet, the lateral line of the fold, normally through the center portion of the hinge, for example, through dashed line 20, would not leave exposed adhesive after the hinge is folded.
FIG. 4 illustrated an embodiment in which the amount of adhesive is minimal. Hinge 11 has at least one, and in a preferred embodiment, only one, longitudinal strip, or line, of adhesive, 27, substantially centered on the contact surface. In the embodiment shown, strip 27 has a non-coated, or open, area, 29, along the middle portion of the hinge to facilitate folding along fold line 20 and mounting as described in the foregoing.
FIG. 5 also illustrates an embodiment in which the adhesive coating is minimal and is in the form of a lateral strips. In such embodiment hinge 11 has at least two lateral, and in a preferred case, only two, strips, or lines, of adhesive, such as, 31 and 33, positioned in opposite halves of the hinge surface to provide an uncoated area, 35, in the center portion of the hinge to facilitate folding and mounting as described above.
From the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made within the present invention without departing from the concepts disclosed. Such modifications shall be deemed to fall within the spirit of the invention as determined by the scope of the appended claims. | 4y
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RELATED APPLICATIONS
The present application is a continuation-in-part application of application Ser. No. 09/020,638, filed on Feb. 9, 1998, abandoned, in the name of Cornelius McDaid and titled CABLE LOCK AND BRACKET.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cable locks, and, more particularly, to a complementary set including a cable lock and mounting bracket for releasably securing the cable lock to a bicycle frame.
2. The Prior Art
Since the invention of the cable bicycle lock and the continued improvement thereof, ways to hold onto the lock when riding the bicycle have been needed. In recent years, different ways of mounting these locks to the bicycle were developed. One such method includes securely mounting the lock head to the bicycle frame so that it does not move. The cable end is removed, by using the key, from the lock head, wrapped around a stationary object, and inserted back into the lock head. The main disadvantage to this mounting method is that the cable must be long enough to reach from where the lock head is mounted, around the stationary object, and back to the lock head. It also prevents the cable lock from being used for any vehicle or other purpose.
A second method includes using a bracket to removably attach the cable lock to the bicycle. Early versions of these brackets use the cable itself to hold onto the bracket. For example, the cable is unlocked, the free end of the cable is inserted through a hole in the bracket until the lock head is within the bracket, and the cable is locked together. The main disadvantage is that the entire length of the cable has to be snaked through the bracket before it can be locked together.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a cable lock and bracket that can be secured to a vehicle without having to disengage the lock.
The present invention includes a cable lock and a complementary bracket. The cable lock has the typical components, with a lock head and a cable. One end of the cable is permanently anchored to the lock head and the other end is releasably attached to the lock head through an aperture in the lock head. A keyway accepts a key for operating the internal locking mechanism. Alternatively, a set of combination dials operates the locking mechanism.
The bracket has an attachment portion and a seat portion. The attachment mounts the bracket to the frame strut. Exemplary attachments include a unitary embodiment, where a single flap of the bracket extends around the frame strut and is secured, and a clamp embodiment, where the bracket is held to the frame strut by a hose clamp or similar device.
The seat has a cavity into which the lock head fits, where the cable extends through an opening at the bottom. The cavity has a funnel shape to act as a stop limiting the distance that the lock head can go into the cavity. Gravity holds the lock head in the cavity. Preferably, the shape of the lock head and cavity are matched so that the lock head fits snuggly to minimize movement of the lock head within the cavity. A gap in the side of the cavity is wide enough to allow for insertion of the cable into the cavity but not wide enough for the lock head to fit through. A notch in the top edge of the cavity provides a location for the cable end inserted into the aperture. The notch, in combination with the cable, can prevent the lock head from rotating within the cavity.
Optionally, the lock is held in the cavity by a latch so that the bracket may be used in various orientations. The latch includes an arm, the lower end of which acts as a spring to allow the upper end to bend, but that returns the arm to its normal, or latched, position. A knob at the top of the arm allows manual bending of the arm from the latched to an unlatched position. A tongue extends from the side of the arm. When in the latched position, the tongue extends into the cavity and into a groove in the side of the lock head. When manually moved to the unlatched position, the tongue is removed from the groove.
Other objects of the present invention will become apparent in light of the following drawings and detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and object of the present invention, reference is made to the accompanying drawings, wherein:
FIG. 1 is a perspective view of the cable lock and bracket of the present invention;
FIG. 2 is a cross-sectional view of the bracket of FIG. 1;
FIG. 3 is a cross-sectional top view of one embodiment of the attachment;
FIG. 4 is a cross-sectional top view of another embodiment of the attachment;
FIG. 5 is a perspective view of the bracket of the present invention including an optional releasable latch; and
FIG. 6 is a cross-sectional view of the bracket of FIG. 5;
DETAILED DESCRIPTION
The cable lock/bracket combination 10 of the present invention is shown in FIG. 1 as attaching a cable-type bicycle lock 14 to a strut 8 of a bicycle. The cable lock 14 has a lock head 16 and a cable 18. The cable 18 is permanently attached to the lock head 16 at an anchor end 20 and is releasably attached to the lock head 16 at a free end 22. The lock head 16 includes a keyway 24 that accepts a key for accessing an internal locking mechanism. When closed, the locking mechanism retains the cable free end 22 through an aperture 26 in the side of the lock head 16. When opened by the key, the locking mechanism releases the free end 22, allowing it to be removed from the aperture 26 so the cable 18 may be snaked through the bicycle and a stationary fixture. Alternatively, a set of combination dials, rather than a key, operates the locking mechanism. The cable 18 is typically composed of braided steel encased in vinyl, but the present invention contemplates that any form of cable may be used.
The bracket 12 attaches to a frame strut 8 and has two sections, an attachment 30 and a seat 32. The attachment 30 is adapted to mount the bracket 12 to the frame strut 8. The present invention contemplates using any form of mounting that is adequate for the task, two of which are briefly described below.
A unitary embodiment 36 of the attachment 30 is shown in FIG. 3. The unitary embodiment 36 consists of a flap 38 that extends from one side of the bracket 12 and wraps around the frame strut 8. The end 40 of the flap 38 has a hole 42 through which a screw 44 extends. The screw 44 is tightened via a nut 46 to secure the bracket 12 to the frame strut 8.
The clamp embodiment 50 of the attachment 30 is shown in FIG. 3. The face 52 of the bracket 12 includes a semi-cylindrical surface. A hose clamp 54 or other similar device extends around the frame strut 8 and through a slot 56 behind the face 52. The clamp 54 is tightened to secure the bracket 12 to the frame strut 8.
At the opposite end of the bracket 12 from the attachment 30 is the seat 32. The seat 32 has a cavity 60, the inner surface of which is shaped somewhat like a funnel. The lock head 16 fits into the cavity 60, where the cable 18 extending from the lock head 16 fits through an opening 62 at the bottom of the cavity 60. Typically, gravity holds the lock head 16 in the cavity 60. The purpose of the funnel shape is to act as a stop limiting the distance that the lock head 16 can go into the cavity 60, thereby preventing the lock head 16 from falling through the cable opening 62. The exact shape of the cavity 60 is not particularly important. The only restrictions are that the lock head 16 can fit into the cavity 60 and that the cable opening 62 is too small for the entire lock head 16 to fit through. Preferably, the shape of the lock head 16 and cavity 60 are matched so that the lock head 16 fits snuggly within the cavity 60. A snug fit minimizes movement of the lock head 16 within the cavity 60.
An improvement over the prior art is a gap 64 in the side of the cavity 60 that allows for insertion of the cable 18 into the cavity 60. Without the gap 64, as in the prior art, the cable 18 would have to be released from the lock head 16 and the free end 22 snaked completely through the cavity 60. The gap 64 provides a much more convenient way to insert the lock head 16 into the cavity 60. The gap 64 should only be wide enough to allow the cable 18 to fit through. It should not be so wide as to compromise the integrity of the bracket 12 or to allow the lock head 16 to fit through.
In the typical cable lock, the aperture 26 into which the free end 22 of the cable 18 is inserted is located on the side of the lock head 16. If the cavity 60 is sized so that the aperture 26 would fall within the cavity 60, a means must be provided to accommodate the cable 18 when the free end 22 is in locked into the aperture 26. A notch 68 in the upper edge 66 of the cavity 60 provides a location for the cable 18.
The notch 68 can also provide a secondary function, which is to prevent the lock head 16 from rotating within the cavity 60. Normally, however, this function is unnecessary if the cavity 60 and lock head are shaped to prevent rotation. For example, in the embodiment of FIG. 1, the lock head has an approximately oval horizontal cross-section, so that it cannot rotate within the cavity 60.
Optionally, the seat 32 has a latch for securing the lock head 16 into the cavity 60, as shown in FIGS. 5 and 6. The latch precludes the need for gravity to hold the lock head 16 in the cavity 60, so that various orientations of the bracket 12 are possible. The latch includes an arm 72 in four sections. The lower end of the spring section 74 is anchored to the bracket 12, as at 76. Extending at about 90° from the upper end of the spring section 74 is an offset section 78, which offsets the knob section 80 from the spring section 74. Extending in the opposite direction from the offset section 78 is a tongue 82.
The arm 72 is positioned so that it can flex between a latched position and an unlatched position. In the latched position, the tongue 82 extends into the cavity 60. In the unlatched position, the tongue 82 does not extend into the cavity 60. The spring section 74 biases the arm 72 to the latched position, so that manual force is needed to move the arm 72 to the unlatched position. When the manual force is removed, the arm 72 returns to the latched position.
When the lock head 16 is within the cavity 60, the tongue 82 fits into a groove 88 in the lock head 16. The upper surface of the tongue 82 is curved downwardly, as at 84, so that the arm 72 is pushed out of the way when the lock head 16 is being inserted into the cavity 60. When the lock head 16 is fully inserted into the cavity 60 and the tongue 82 is aligned with the groove 88, the arm 72 snaps back so that the tongue 82 is in the groove 88. The lower surface of the tongue 82 and the lower surface of the groove 88 are flat so that the lock head 16 cannot be pulled from the cavity 60. The lock head 16 is removed from the cavity 60 by manually pulling back on the knob 80 so that the tongue 82 comes out of the groove 88, and then pulling the lock head 16 from the cavity 60.
The arm 72 can be located anywhere around the circumference of the seat 32. Most preferably, however, it is located in the section of the seat nearest the attachment 30. This gives the most support and protection to the arm 72. Because the arm 72 has a protruding knob 80 and is somewhat flexible, it would be vulnerable to having an external object catch on it and snap it off if not protected.
Preferably, the bracket 12 is composed of a rigid plastic, such as ABS, nylon 6/6, or glass-filled nylon 6/6.
Thus it has been shown and described a cable lock and bracket which satisfies the objects set forth above.
Since certain changes may be made in the present disclosure without departing from the scope of the present invention, it is intended that all matter described in the foregoing specification and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application 62/037,094 filed on Aug. 13, 2014, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present disclosure relates in general to the fields of solar cells, and more particularly to wide band gap passivation solar cell structure.
BACKGROUND
[0003] Passivated emitter solar cells PESC, passivated emitter rear cells PERC, and passivated emitter rear locally diffused PERL solar cells are some of most commonly used cell architectures in the solar industry. FIGS. 1A , 1 B, and 1 C show schematic diagram for PESC, PERC, and PERL solar cells, respectively. As may be noted in FIGS. 1A , 1 B, and 1 C, PERL solar cells may be more complicated than PERC and PESC cells; however, more complicated structures may also be capable of providing higher efficiency. Traditionally, the solar industry has been extremely conservative to move to complicated structures because of rigid cost controls. However, the recent push for higher efficiency has spurred the trend to migrate from PESC to PERC and to PERL. In the highest efficiency PERL design (a special case of PERC), most of the rear surface is passivated by a high quality passivation (traditionally SiO 2 and more recently a combination of Al 2 O 3 and SiN) and contact areas are opened in the passivation to touch the metal and draw current. In the case of PERL, these areas are further shielded from metal recombination by providing a localized heavy doping of the same type as the substrate, known as back surface field or a localize BSF. Providing extra shielding of metal recombination and providing passivation requires additional process steps and high quality metal recombination shielding is challenging to attain.
[0004] Many industrial solar cells have been based on a p-type substrate. For example, it may be easier to make a PERL cell on p-type substrate because aluminum Al, a commonly used material which serves as solar cell metal, may be fired to make it serve as the p++ localized dopant at the same time. However, recently, there is also a push to move to n-type substrates because of much higher efficiency and lifetimes (without or minimal light induced degradation LID) on these substrates. Making a PERL cell may add more complexity on an n-type substrate as the localized BSF has to be of n++ polarity which cannot necessarily be formed using backside Al metal.
[0005] In addition to the aforementioned architectural and substrate type migrations toward higher efficiency, on the front side of the solar cell the industry is steadily moving toward another high efficiency element in a selective emitter structure. Once again, as previously noted, the trade-off for higher efficiency may be the addition of more process steps and cost.
BRIEF SUMMARY OF THE INVENTION
[0006] Therefore, a need has arisen for a solar cell structure having improved efficiency and reduced fabrication complexity. In accordance with the disclosed subject matter, rear wide band gap passivated—passivated emitter rear cells are provided which may substantially eliminate or reduce disadvantages and deficiencies associated with previously developed solar cell structures.
[0007] According to one aspect of the disclosed subject matter, a photovoltaic solar cell comprises a light absorbing layer of n-type crystalline silicon is provided. An emitter layer is on the front side of the n-type crystalline silicon. A front passivation layer physically contacts the emitter layer. A front metal contact is on the front passivation layer and contacts the emitter layer. A back layer of wide bandgap semiconductor physically contacts a back side of the n-type crystalline silicon layer. A back metal contact physically contacts the wide bandgap semiconductor layer.
[0008] These and other aspects of the disclosed subject matter, as well as additional novel features, will be apparent from the description provided herein. The intent of this summary is not to be a comprehensive description of the claimed subject matter, but rather to provide a short overview of some of the subject matter's functionality. Other systems, methods, features and advantages here provided will become apparent to one with skill in the art upon examination of the following FIGUREs and detailed description. It is intended that all such additional systems, methods, features and advantages that are included within this description, be within the scope of any claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The features, natures, and advantages of the disclosed subject matter may become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference numerals indicate like features and wherein:
[0010] FIGS. 1A , 1 B, and 1 C show schematic diagram for PESC, PERC, and PERL solar cells, respectively;
[0011] FIG. 2 is a cross-sectional diagram showing a high-level RGP-PERC cross-section using an n-type substrate having blanket back metal; and
[0012] FIG. 3 is a cross-sectional diagram showing a high-level RGP-PERC cross-section using an n-type substrate having patterned back metal.
DETAILED DESCRIPTION
[0013] The following description is not to be taken in a limiting sense, but is made for the purpose of describing the general principles of the present disclosure. The scope of the present disclosure should be determined with reference to the claims. Exemplary embodiments of the present disclosure are illustrated in the drawings, like aspects and identifiers being used to refer to like and corresponding parts of the various drawings.
[0014] And although the present disclosure is described with reference to specific embodiments and components, one skilled in the art could apply the principles discussed herein to other solar cell structures and materials (e.g., mono crystalline silicon or multi-crystalline silicon), fabrication processes (e.g., various deposition methods and materials such as metallization materials), as well as alternative technical areas and/or embodiments without undue experimentation.
[0015] Rear Wide Band Gap Passivated-Passivated Emitter Rear Cells PERC, referred to as RGP-PERC herein, structures and fabrication solutions are provided. The solar cell structure solutions leverage the relative simplicity of the PERC cell to increases cell efficiency while reducing the number of fabrication process steps—in other words the solutions provided both reduce the complexity and improve the efficiency of the standard PERC cell. RGP-PERC not only allows for cell efficiency much higher than a standard PERC cell, RGP-PERC also allows for cell efficiency higher than the more complex, expensive, and traditionally higher efficiency PERL cell architecture—in other words the innovative solution outlined in this document allows solar cells to achieve performance better than that possible by PERL, yet at a substantially reduced number of process steps.
[0016] The present application provides a wide bandgap rear passivation which provides not only high quality passivation to silicon, but at the same time provides superior contact to the right type of carriers thus obviating the need of patterning dielectrics and doping areas in the back as it relies on blanket depositions of the film. The wide band gap semiconductor passivation in the back is different material/film for p-type and n-type substrate.
[0017] Additionally, high quality solar cell front (frontside) passivation and doping is provided which may further reduce fabrication process steps. Forming doped Al 2 O 3 on the cell frontside (e.g., doped Al 2 O 3 deposited using atmospheric pressure chemical vapor deposition APCVD) provides superior passivation and also provides a dopant source (for n-type solar cell having a boron based emitter) thus further reducing fabrication process steps.
[0018] FIG. 2 is a cross-sectional diagram showing a high-level RGP-PERC cross-section using an n-type substrate having blanket back metal. N-type substrate 2 has a front side emitter layer 8 and front side passivation layer or stack 10 (e.g., Al 2 O 3 ). Front metal 12 contact front side emitter layer 8 through front side passivation layer or stack 10 . Rear (or back) wide band gap layer or stack 4 (e.g., TiO x ) is on the rear (or back) of n-type substrate 2 . Blanket back metal 6 is on wide band gap layer or stack 4 .
[0019] FIG. 3 is a cross-sectional diagram showing a high-level RGP-PERC cross-section using an n-type substrate having patterned back metal. N-type substrate 14 has a front side emitter layer 20 and front side passivation layer or stack 22 (e.g., Al 2 O 3 ). Front metal 24 contact front side emitter layer 20 through front side passivation layer or stack 22 . Rear (or back) wide band gap layer or stack 16 (e.g., TiO x ) is on the rear (or back) of n-type substrate 14 . Patterned back metal 18 is on wide band gap layer or stack 16 .
[0020] The device is possible for both n and p-type silicon substrates. A defining characteristic of the RGP-PERC structure is that it is passivated in the back/rear (non-sunnyside) of the silicon semiconductor using a single wide band gap semiconductor/dielectric or a multi-layer dielectric stack which consists of a wide bandgap semiconductor. This is followed by a suitable metal on the back which may be either blanket (as shown in FIG. 2 ) or patterned (as shown in FIG. 2 ). Patterned metal allows for a bifacial solar cell implementation by letting the light through.
[0021] For example, in consideration of other factors such as cell structure and fabrication, the rear passivating wide band gap semiconductor/dielectric of the RGP-PERC should satisfy the following three important properties: it should allow the passing of the suitable photo carrier (electrons for n-type and holes for p-type) with minimal contact resistance; it should be a high quality passivation layer with low surface recombination velocity (e.g., a surface recombination velocity SRV less than 20 cm/s); it should present a large and effective barrier for the other photo carrier which is not supposed to go to the rear contact (holes for n-type and electrons for p-type semiconductor).
[0022] The RGP-PERC using an n-type substrate may have a wide band gap semiconductor such as titanium oxide TiOx followed by metal on the rear side. This allows the rear stack to be simple while at the same time, because the surface passivation is excellent, hole rejection is superior, and contact resistance to electrons is relatively low, the stack provides a relatively high performance from the stand point of Voc and FF. Note, in a conventional traditional solar cell scheme this type of performance for n-type substrates would be accomplished with a PERL design requiring complex steps (for example, laser fired doping) to create heavy n+ doping under the metal on the rear side while using passivation, such as Al 2 O 3 +SiN, everywhere else on the cell rear side. Not only is this conventional traditional solar cell scheme more cumbersome, the quality of the passivation under the contact with n+ is inferior to that created using TiO x .
[0023] It should be noted that TiO x is an example of a wide band gap material that may be used for this purpose. In general, a single or multi-layer stack (such as, but not limited to, Al 2 O 3 +TiO x or Al 2 O 3 +ZnO or any combinations) which satisfies the properties following may be used to form RGP-PERC. Key properties for this rear single or multi-layer material stack are: there should be at least one wide bandgap material which creates a large band offset with holes; the stack creates reasonably good passivation to n-type silicon (e.g., SRV less than 200 cm/s); and, the stack gives reasonable contact resistance to electrons.
[0024] In a specific and particularly advantageous embodiment for an n-type silicon PERC, the rear wide band gap semiconductor material is titanium oxide TiO x deposited using atomic layer deposition (ALD) which serves as an n-doped wide bandgap semiconductor. Alternative deposition techniques such as physical vapor deposition PVD of TiO x may also be suitable if the qualities of the deposited film may be similar to those obtained using ALD. The TiO x may be annealed at a temperature in the range of 375 to 450° C. either in N 2 or in a forming gas anneal FGA environment (e.g., 400° C. in FGA) to activate it. The bandgap of TiO x is approximately 3.2 eV with majority of the band discontinuity in the valence band with silicon (e.g., approximately 2.1 eV). The conduction band of the TiO x tends to line up with the conduction band of silicon. This band alignment presents an excellent low contact resistance flow of carriers for electrons (superior ohmic contact) and a large barrier of approximately 2.1 eV to holes. This large barrier to holes serves as a superior rejection of the holes from the back side base. In addition, ALD deposited TiO x has the property of being an excellent passivation, for example providing SRV less than 50 cm/s while being relatively thin (e.g., having a thickness less than 5 nm). The relative thin thickness is also an attribute provides the aforementioned low contact resistance. Thus, TiO x satisfies the aforementioned properties and attributes of an RGP-PERC single or multi-layer material rear stack.
[0025] For TiO x , the cell backside metal may be for example either aluminum, titanium by itself or followed by another metal such as aluminum to increase conductivity. The addition of TiO x wide bandgap semiconductor unpins the Fermi level of the metal and raises it close to the charge neutrality level CNL of TiO x which itself is close to the conduction band of silicon. This substantially lowers the barrier for electrons to flow between metal and silicon.
[0026] Alternatively nickel may be used as a backside metal. Although, nickel's vacuum workfunction is close to the valence band of silicon, it is likely that when deposited on top of a material like TiO x , nickel's workfunction gets pulled toward the CNL of TiO x which is near the conduction band of silicon—thus providing a lower barrier for electrons. Nickel as a backside may be advantageous as there are relatively easy patterned deposition schemes available with nickel (e.g., nickel deposition using ink jet).
[0027] In another embodiment, a rear wide band gap semiconductor/dielectric (and passivation) may be Al 2 O 3 , for example an atomic layer deposited ALD Al 2 O 3 . Alternatively Al 2 O 3 deposition techniques such as metal organic chemical vapor deposition MOCVD may be used. Because Al 2 O 3 is a true insulator, it is imperative that an Al 2 O 3 layer be thin (e.g., having a thickness less than 3 nm) to ensure that the contact resistance may be low because of tunneling. Al 2 O 3 also serves as an excellent passivation for n-type silicon. A tradeoff with Al 2 O 3 is that as it gets thinner its passivation quality reduces. However, there is a possibility of an optimization with respect to Al 2 O 3 thickness such that both passivation and contact resistance are sufficient for RGP-PERC.
[0028] In yet another embodiment of the RGP-PERC, the back side deposited wide bandgap semiconductor/dielectric may be a bilayer of Al 2 O 3 and TiO x . This bilayer having a thin Al 2 O 3 (e.g., having a thickness less than 2 nm) is characterized is a high quality passivation and contact for electrons. In one possible fabrication process flow, the bilayer may be deposited in-situ inside an ALD reactor. Other bilayers such as Al 2 O 3 and ZnO or a combination of Al 2 O 3 , ZnO, TiO in single or multi-layer formation which meet the properties of hole rejection, passivation quality, and contact resistance may be used as a rear single wide band gap semiconductor/dielectric or a multi-layer dielectric stack.
[0029] A bifacial solar cell is compatible with all the rear wide band gap/dielectric embodiments provided herein. Functionally, the back side of the solar cell structure provided may be bifacial to allow the light to be captured from the rear side. This may be accomplished by patterning the backside metal in a grid or other pattern to allow light to come through. Alternatively a patterned metal may be deposited using techniques such as inkjet or screen printing. An additional indium tin oxide ITO layer may be deposited on the solar cell backside as an anti-reflection coating ARC. For example, ITO may be grown using ALD reactor in-situ with the other wide band gap semiconductors or ITO may be sputtered deposited. Silicon nitride SiN may also be used as a solar cell backside ARC.
[0030] Relating to the n-type silicon solar cell frontside, solar cells having doped Al 2 O 3 which serves the dual function of being a superior passivation and the dopant source for the emitter while allowing for the reduction fabrication process steps are provided. For example, atmospheric pressure chemical vapor deposition APCVD deposited Al 2 O 3 despite being driven at a high temperature retains its passivation quality yielding positive Jos on boron emitter down to less than 20 fA/cm 2 . Additionally, the Jo values are found to remain low with the anneal APCVD Al 2 O 3 for lower sheet resistivity (rho) emitters down to 50 ohms/sq. Thus providing a high performance without necessarily going to a selective emitter process, thus saving additional process steps.
[0031] Front side options for combination with the aforementioned backside options of an RGP-PERC include a standard PERC non-selective emitter and selective emitter and non-selective emitter option using APCVD doped Al 2 O 3 . Front side embodiments which may be used with the rear side stack include, but are not limited to: Al 2 O 3 selective emitter, non-selective emitter, APCVD Al 2 O 3 emitter, and non Al 2 O 3 standard stacks with SiN. Note, a class of front side possibilities include options where the boron, p+ emitter is passivated using Al 2 O 3 (followed by an ARC in the form of SiN or ITO) are used in combination with the RGP-PERC rear side. Another class includes SiN or a thin Sift layer followed by SiN used for this purpose. With both of these options, either selective or non-selective emitter options are possible.
[0032] Two manufacturing solutions for an Al 2 O 3 boron passivated front side for selective and non-selective emitter are provided. These fabrication solution options allow for reducing manufacturing steps and when taken in conjunction with the rear side fabrication solution options provided herein dramatically reduce the processing steps and cost for manufacturing an RGP-PERC solar cell. An Al 2 O 3 boron passivated front side is currently viable with an n-type substrate as it is applicable for a boron doped emitter.
[0033] Inventive aspects pivot on the fact that an APCVD doped Al 2 O 3 is used as both the passivation and the dopant source. Al 2 O 3 is doped with boron and is initially deposited using APCVD. It is then annealed at a high temperature (e.g., a temperature in the range of 950 to 1100° C.) to drive the boron into silicon and form an emitter. Conventional traditional wisdom is that since Al 2 O 3 will start to crystallize at these temperatures, the passivation quality may deteriorate thus requiring the Al 2 O 3 to be stripped and a fresh Al 2 O 3 deposited. However, an optimal anneal temperature is used where despite Al 2 O 3 crystallizing, its passivation quality remains relatively superior thus obviating the need for stripping it. Passivation quality has been measured to have a Jo of less than 15 fA/cm 2 . The mechanism is thought to be related to the interfacial layer. APCVD deposited interfacial layer becomes richer in Si as it approaches silicon. The silicon richness allows the interfacial layer to not crystallize during anneal and thus retain its passivation qualities. This film may also be used as an adequate ARC when an adjusted thickness of SiN is formed on top.
[0034] Using these properties, a non-selective emitter front side may fabricated simply by using the following steps. Note the sequence may be altered when integrated with RGP-PERC fabrication as described below.
[0035] 1. APCVD boron doped Al 2 O 3
[0036] 2. Anneal at an optimal temperature (950 to 1100° C.) in N2 environment
[0037] 3. SiN deposition
[0038] 4. Laser ablation using pico-second laser
[0039] 5. Metallization (screen printed or PVD)
[0040] If appropriate metallization paste is used, the laser opening can be eliminated and paste can be fired through the SiN/Al 2 O 3 stack thus reducing the process flow above to four steps.
[0041] While the above non-selective emitter may be expected to be superior as compared to a conventional non-selective emitter because of the ability for Al 2 O 3 to passivate boron emitter with a low Jo despite the doping concentration increasing, if selective emitter may be fabricated, for example, with the following modification to the process outlined above.
1. APCVD lightly boron doped Al 2 O 3 2. Laser open areas where there is heavily doped emitter 3. APCVD heavy boron doped Al 2 O 3 4. Anneal at an optimal temperature (950 to 1100° C.) in N2 environment 5. SiN deposition (thickness of SiN adjusted to provide high quality ARC along with the already present Al 2 O 3 ) 6. Laser ablation using pico second laser OR skip if suitable firing paste is used 7. Metallization (screen printed or PVD)
[0049] From device point of view, whenever non-selective emitter is used for cost reasons as compared to a selective emitter, the following trade-offs in performance must be considered: Jo of emitter (Voc); Jo of contact recombination (Voc); sheet resistance of the emitter (FF); contact resistance of the emitter (FF); and, blue response of the cell (Jsc). Out of the these five device factors, Jo of contact recombination, contact resistance of the emitter, and sheet resistance of the emitter prefer heavier doping (smaller sheet rho), while Jo of emitter and blue reasons of the cell prefer light doping (higher sheet rho). With a selective emitter and by having an option of putting a heavier doping under the contact and a lighter doping in the emitter passivation areas, all five parameters may be optimized. Non-selective emitters may not have this option.
[0050] However, going to Al 2 O 3 with APCVD, the emitter Jo may remain despite emitter sheet resistance as low as 50-70 ohms/sq. This helps expand the process window for optimization without a selective emitter. With a non-selective emitter and APCVD Al 2 O 3 , by going to lower sheet resistivity (rho), the listed parameters outside of blue response above are addressed while the blue response needs to be optimized. Thus, APCVD doped Al 2 O 3 with non-selective emitter for the PERC cell not only reduces the number of process steps compared to a non-selective emitter standard PERC but also may provide performance approaching that of a selective emitter.
[0051] In the case of a p-type silicon solar cell RGP-PERC, nickel oxide NiO may be used for the rear wide bandgap semiconductor/dielectric and Al 2 O 3 plus NiO for the front side structure.
[0052] Representative exemplary fabrication process flows are provided below organized by relevancy to n-type silicon. N-type silicon fabrication process flows may be categorized according to the following characteristics: whether the emitter is passivated by Al 2 O 3 +SiN or only SiN; whether the device has a selective emitter; whether the device is bifacial or unifacial; and, the metallization strategy.
[0053] Relating to metallization strategy, exemplary backside metallization fabrication options and material choice for an RGP-PERC with n-type substrate include PVD of aluminum, titanium, or titanium plus aluminum or nickel inkjet deposition. Exemplary frontside metallization fabrication options and material choice for an RGP-PERC with n-type substrate may be characterized the use of laser processing. For example, if suitable metallization paste is used and no laser opening of the frontside layer or stack (e.g., Al 2 O 3 ) is used on the front then aluminum paste may be screen printed and fired. If laser ablation is used to open the frontside layer or stack, the following example metals and deposition methods may be performed: a patterned screen print of aluminum; patterned PVD of aluminum, copper, titanium, or nickel; or, patterned metal inkjet of nickel.
[0054] Subsequently, to increase conductivity, additional metal may be formed on top of already patterned metal. Whether or not laser is used, the metal may be built up for example by screen printing silver or plating copper on the previously formed front side metal.
[0055] Relating to the backside metal choice, it may be advantageous that the selected metal for use alongside TiO x has a workfunction which is closer to that which aligns with the conduction band of silicon. Hence, Al (4.1 eV) and Ti (˜4.3 eV) may be considered ideal materials for this purpose. However, Ni may also be used albeit with a slightly higher but acceptable contact resistance. For example, when TiO x is inserted between silicon and the metal, the work function of the metal tends to gravitated toward the charge neutrality level (CNL) of TiO x independent of the vacuum work function of the metal. The CNL of TiO x is relatively close to the conduction band of silicon, hence despite that nickel's vacuum workfunction is close to the valence band of silicon, nickel's workfunction tends to approach the conduction band of silicon when on top of TiO x . In addition to the above listed deposition techniques for the backside (e.g., screen printing), other suitable deposition techniques which may provide direct patterned metallization deposition or blanket metallization deposition and subsequent metallization patterning are implicitly included.
[0056] For n-type substrates, front metal makes contact to the boron doped emitter. Thus front side metal material should be selected such that it makes high quality contact to p-type boron doping, for example Al, Ni, and Ti. In cases where there is no explicit opening of the frontside layer or stack (e.g., Al 2 O 3 ), the metal may need to be fired (e.g., using standard paste screen print/fire sequence with a fritted paste or using a laser).
[0057] For the case where an explicit contact is opened using a laser, similar metal types are possible including materials such as Al, Ti, and Ni. However, in this case there is a larger availability of deposition techniques as the metal need not be fired and is in direct contact with the emitter. In an advantageous fabrication process, a patterned seed layer is first deposited (e.g., a patterned see layer deposited using techniques such as inkjetting of, for example, nickel, or direct patterned screen printing of, for example, aluminum). Subsequently, additional metal may be deposited, for example, using screen printing of silver or plating to dramatically increase the conductivity to levels less than 5 ohm/sq sheet resistance to allow single digit metal coverage (to obtain high Jsc).
[0058] The following tables are provided as descriptive process flow examples for making an RGP-PERC. The process flows provided herein are representative flows serving as examples and should not be interpreted in a limited sense. Tables 1 and 2 show representative fabrication flows for making an RGP-PERC on n-type silicon without an explicit frontside passivation opening process.
[0000]
TABLE 1
Metal screen print on front and back. Should use aluminum paste
on the back which does not go through TiO x at the temperature
the front past is fired through SiN x .
1
Single side Texture
2
APCVD B Doped Al2O3 on the front side
3
Anneal to Form the emitter on the front
4
ALD TiO2 Backside after surface clean
5
PECVD SiNx Deposition Frontside
6
FRONT: Al Screen Print/Fire + Ag screen print/fire to increase
conductivity, BACK: Al screen print
[0000]
TABLE 2
Metal screen print on front and metal PVD on back.
1
Single side Texture
2
APCVD B Doped Al2O3 on the front side
3
Anneal to Form the emitter on the front
4
ALD TiO2 Backside after surface clean
5
PECVD SiNx Deposition Frontside
6
FRONT: Al Screen Print/Fire + Ag screen print/fire to increase
conductivity
7
AL PVD blanket on the back
[0059] Tables 3 through 8 show representative fabrication flows for making an RGP-PERC on n-type silicon with laser opening and various metallization options and no selective emitter and Al 2 O 3 passivated emitter.
[0000]
TABLE 3
Laser open, metal screen print on front and metal PVD on back.
1
Single side Texture
2
APCVD B Doped Al2O3 on the front side
3
Anneal to Form the emitter on the front
4
ALD TiO2 Backside after surface clean
5
PECVD SiNx Deposition Frontside
6
Laser based contact open on the front
7
Al + Ag Paste print front
8
PVD Al on the back
[0000]
TABLE 4
Laser open, metal inkjet on front and metal PVD on back.
1
Single side Texture
2
APCVD B Doped Al2O3 on the front side
3
Anneal to Form the emitter on the front
4
ALD TiO2 Backside after surface clean
5
PECVD SiN x Deposition Frontside
6
Laser based contact open on the front
7
PVD Al on the back
8
Inkjet Ni on the front (Cu Plating or Ag Screen print on top)
[0000]
TABLE 5
Laser open, metal inkjet on front and metal inkjet on back.
1
Single side Texture
2
APCVD B Doped Al2O3 on the front side
3
Anneal to Form the emitter on the front
4
ALD TiO2 Backside after surface clean
5
PECVD SiN x Deposition Frontside
6
Laser based contact open on the front
7
Inkjet Ni on the front and on the back
8
Optional Ag print of Cu plating on the front
[0000]
TABLE 6
Laser open, metal PVD on front and back. The flow may utilize additional
metal patterning process which may be particularly advantageous if the
current in the front may be reduced.
1
Single side Texture
2
APCVD B Doped Al2O3 on the front side
3
Anneal to Form the emitter on the front
4
ALD TiO2 Backside after surface clean
5
PECVD SiN x Deposition Frontside
6
Laser based contact open on the front
7
Patterned PVD Al + screen print Ag (if necessary)
8
PVD Al on the back
[0000]
TABLE 7
Laser open, metal PVD on front and metal screen print on back.
The flow may utilize an additional metal patterning process.
1
Single side Texture
2
APCVD B Doped Al2O3 on the front side
3
Anneal to Form the emitter on the front
4
ALD TiO2 Backside after surface clean
5
PECVD SiN x Deposition Frontside
6
Laser based contact open on the front
7
Patterned PVD Al + screen print Ag (if necessary)
8
Screen print on back and fire
[0000]
TABLE 8
Laser open, metal screen print on front and back.
1
Single side Texture
2
APCVD B Doped Al2O3 on the front side
3
Anneal to Form the emitter on the front
4
ALD TiO2 Backside after surface clean
5
PECVD SiN x Deposition Frontside
6
Laser based contact open on the front
7
Al Paste print front (non-fritted), Al paste print back (non-fritted),
Cofire, Additional SP/fire Ag on Front
[0060] Other deposition techniques and adjusted process sequence may be possible and apparent by those skilled in the art. For example instead of an ARC using PECVD SiN ARC an ITO based ARC using either PVD deposition or ALD deposition may be utilized.
[0061] Several fabrication steps in the process flows provided are not explicitly mentioned. For example, these may include edge isolation, saw damage removal, and an anneal of TiO 2 film after ALD if the SiN deposition temperature does not anneal TiO 2 film. If a TiO 2 film anneal is required, it may be performed in an FGA or N62 environment at temperatures in the range of 375 to 450° C. (e.g., 425° C. in FGA environment).
[0062] Advantageous aspects of the metallization options provided herein may include cases where the back metal is PVD Al, PVD Ti/Al, or inkjet Ni (if the contact resistance is found to be acceptable with Ni on TiO x ), and cases where the front metallization fabrication uses contact opening process to open a contact to p-doped silicon through the front passivation using laser. Subsequently, either Al paste, patterned PVD, or Ni inkjet followed by either Ag screen print or plating may be used (only if conductivity requirements are high) to form the front metal. Al paste which can be fired in temperature ranges between 510 to 560° C. and makes an excellent contact to p-type silicon down to 180 ohms/sq sheet resistance may be used. The conductivity of this Al paste may be brought down to 50 uohm-cm. This Al paste may serve as an excellent patterned metal seed along with patterned nickel inkjet to make high quality contact to the silicon emitter. Subsequently, metal for increased conductivity may be formed using techniques such as, but not limited to Ag screen print or Cu plating.
[0063] Tables 9 through 14 show representative fabrication flows for making an RGP-PERC on n-type silicon where the emitter doping layer is stripped and a new Al 2 O 3 layer is deposited. While the re-deposited Al 2 O 3 may be advantageously deposited using ALD, other techniques such as PECVD Al 2 O 3 followed by SiN or APCVD Al 2 O 3 may also be used. Note, that if ALD Al 2 O 3 is performed, it is desirable that the Al 2 O 3 thickness be greater than 10 nm to provide high quality passivation. Optionally, ALD Al 2 O 3 and ITO may be performed in-situ in the ALD reactor. ITO may form the ARC and obviate the need for SiN.
[0064] Table 9 shows a representative fabrication flow with Al 2 O 3 and SiN passivation stack on the cell front side and advantageous metallization fabrication of Al paste print followed by Ag paste print on the front side after opening the contact. Al is formed by PVD on the cell back side on top of TiO x . Alternatively, as previously described, Ni inkjet may be used as a seed layer followed by plating or screen print of Ag.
[0000]
TABLE 9
Laser open, metal screen print on front and metal PVD on back.
1
Single side Texture
2
APCVD Boron doped oxide (BSG) or boron doped AL2O3
3
Anneal to Form the emitter on the front
4
Etch away all APCVD
5
PECVD Al2O3 and SIN on the front
6
ALD BACK TiO x by itself (unifacial) or TiO x /ITO (ITO if bifacial)
7
Laser based contact open on the front
8
Al + Ag Paste print front
9
AL PVD blanket on the back (patterned if bifacial)
[0065] Tables 10 through 14 shows representative fabrication flows with a stripped dopant source and using ITO ARC instead of SiN ARC and where the ITO is deposited in-situ in the ALD reactor after Al 2 O 3 . Fabrication flows of Tables 10 through 14 show Al 2 O 3 passivated emitter and non-selective emitter. In the case of complexity of firing the metal paste through ITO, the contact may be opened (e.g., laser opening) and SiN may be used as ARC. A parallel set of process flows where the ARC is SIN instead of ITO may be obtained by the person skilled in the art.
[0000]
TABLE 10
Metal screen print on front and metal PVD on back.
1
Single sided Texture
2
APCVD Boron doped oxide (BSG) or boron doped AL2O3
3
Anneal to Form the emitter on the front
4
Etch away all APCVD
5
ALD front Al2O3/ITO and back TiO x /ITO (ITO if bifacial)
6
Al + Ag Screen Print/Fire on Front (Al for contact resistance)
7
AL PVD blanket on the back (patterned if bifacial)
[0000]
TABLE 11
Laser open, metal screen print on front and metal PVD on back.
1
Single side Texture
2
APCVD Boron doped oxide (BSG) or boron doped AL2O3
3
Anneal to Form the emitter on the front
4
Etch away all APCVD
5
ALD front Al2O3/ITO and back TiO x /ITO (ITO if bifacial)
6
Laser based contact open on the front
7
Al + Ag Paste print front (Al for the contact resistance)
8
AL PVD blanket on the back (patterned if bifacial)
[0000]
TABLE 12
Laser open, metal PVD on front and back.
1
Single sided Texture
2
APCVD Boron doped oxide (BSG) or boron doped AL2O3
3
Anneal to Form the emitter on the front
4
Etch away all APCVD
5
ALD front Al2O3/ITO and back TiO x /ITO (ITO if bifacial)
6
Laser based contact open on the front
7
Patterned PVD Al on the front + Ag screen print (if necessary)
8
AL PVD blanket on the back (patterned if Bifacial)
[0000]
TABLE 13
Laser open, metal inkjet on front and metal PVD on back.
1
Single sided Texture
2
APCVD Boron doped oxide (BSG) or boron doped AL2O3
3
Anneal to Form the emitter on the front
4
Etch away all APCVD
5
ALD front Al2O3/ITO and back TiO x /ITO (ITO if bifacial)
6
Laser based contact open on the front
7
AL PVD blanket on the back (patterned if bifacial)
8
Inkjet Ni on the front + Cu plating (if required)
[0000]
TABLE 14
Laser open, metal inkjet on front and back.
1
Single sided Texture
2
APCVD Boron doped oxide (BSG) or boron doped AL2O3
3
Anneal to Form the emitter on the front
4
Etch away all APCVD
5
ALD front Al2O3/ITO and back TiO x /ITO (ITO if bifacial)
6
Laser based contact open on the front
7
Inkjet patterned Ni on the front + and Ni on the
back + Cu plating (if required)
[0066] Various exemplary fabrication flows provided above (particularly those involving ITO). A bifacial cell RGP-PERC is similar to a unifacial RGP-PERC with two noted modifications. A bifacial RGP-PERC may benefit from an ARC on the back side which for example, in one advantageous embodiment may be grown in-situ with the TiO x in the back in the same ALD reactor. Alternatively, ITO may also be sputtered on top of TiO x . The second noted modification is that the metal in the back should not be blanket but instead patterned so that the light can get through.
[0067] Tables 15 through 18 show representative fabrication flows for making a bifacial RGP-PERC on n-type with Al 2 O 3 passivated emitter and non-selective emitter (NSE).
[0000]
TABLE 15
Metal screen print on front and metal PVD on back.
1
Single sided Texture
2
APCVD B doped Al2O3 on the front side
3
Anneal to Form the emitter on the front
4
ALD TiO2 Backside followed by ALD ITO in the same machine
5
PECVD SiN x Deposition Frontside
6
Al Screen Print/Fire on Front
7
Patterned AL PVD on the back
[0000]
TABLE 16
Laser open, metal screen print on front and metal PVD on back.
1
Single sided Texture
2
APCVD B doped Al2O3 on the front side
3
Anneal to Form the emitter on the front
4
ALD TiO2 Backside followed by ALD ITO in the same machine
5
PECVD SiN x Deposition Frontside
6
Laser based contact open on the front
Al Paste print front
7
Patterned AL PVD on the back
[0000]
TABLE 17
Laser open, metal inkjet on front and metal PVD on back.
1
Single side Texture
2
APCVD B Doped Al2O3 on the front side
3
Anneal to Form the emitter on the front
4
ALD TiO2 Backside followed by ALD ITO in the same machine
5
PECVD SiN x Deposition Frontside
6
Laser based contact open on the front
7
Patterned AL PVD on the back
8
Inkjet Ni on the front and optional cu plating if required
[0000]
TABLE 18
Laser open, metal inkjet on front and back.
1
Single side Texture
2
APCVD B Doped Al2O3 on the front side
3
Anneal to Form the emitter on the front
4
ALD TiO2 Backside followed by ALD ITO in the same machine
5
PECVD SiN x Deposition Frontside
6
Laser based contact open on the front
7
Inkjet Ni on the front and on the back with an optional cu
plating if required
[0068] Metallization schemes mentioned for the unifacial cell may be applicable also be applicable in the fabrication of a bifacial structure. Additionally, the stripped APCVD AL 2 O 3 fabrication processes may also be applicable.
[0069] Among other embodiments, the following exemplary embodiments are specifically provided herein.
[0070] For a non-bifacial with single dielectric stack (TiO x , NiO, and Al 2 O 3 ) specific embodiments include, but are not limited to the following:
A front contact solar cell where the non-sunny (rear) interface consists of silicon, wide-bandgap semiconductor and metal
a. A front contact silicon solar cell where the silicon is n-doped with a wide band gap semiconductor and metal constitute the rear interface b. Where the wideband gap semiconductor such that its conduction band lines up with silicon for n-type solar cell and valence band exhibits a large band discontinuity with silicon's valence band
i. Where wide bandgap semiconductor provides excellent passivation to silicon ii. Where wide band gap semiconductor provides a high rejection barrier for holes iii. Where the wide band gap semiconductor is titanium oxide deposited by atomic layer deposition iv. Where the wide band gap dielectric is aluminum oxide deposited by atomic layer deposition
c. Where the metal in the back is blanket and consists of a vacuum workfunction which is close to the conduction band of silicon
i. Where the metal in the back is aluminum deposited using physical vapor deposition ii. Where the metal in the back is Al deposited using screen printing metal paste. iii. Where the metal in the back is titanium deposited by various deposition schemes such as ink jet and PVD.
d. Where the metal in the back is patterned, thus forming a bifacial cell, and consists of a workfunction which is close to the conduction band of silicon,
i. Where the metal in the back is aluminum deposited using physical vapor deposition ii. Where the metal in the back is Al deposited using screen printing metal paste. iii. Where the metal in the back is titanium deposited by various deposition schemes.
A front contact silicon solar cell where the silicon is p-doped with a wideband gap semiconductor and metal constitute the rear interface
i. Where wide bandgap semiconductor provides excellent passivation to p-type silicon ii. Where wide bandgap semiconductor provides a high rejection barrier for electrons iii. Where the wide bandgap semiconductor is nickel oxide deposited by atomic layer deposition or other means iv. Where the wide bandgap dielectric is Al 2 O 3 deposited using ALD or other means.
b. Where the metal in the back is blanket and consists of a workfunction which is close to the valence band of Silicon
i. Where the metal in the back is Ni deposited using physical vapor deposition ii. Where the metal in the back is Ni deposited using inkjet.
c. Where the metal in the back is patterned forming a bifacial cell and consists of a workfunction which is close to the valence band of silicon.
i. Where the metal in the back is Nickel deposited using physical vapor deposition ii. Where the metal in the back is Ni deposited using inkjet
[0095] For a front contact solar cell where the front (sunny-side) emitter passivation is Al 2 O 3 in combination with the rear (non-sunny side) interface consisting of silicon, wide-bandgap semiconductor, and metal
A front contact solar cell where the front Al 2 O 3 is deposited using APCVD A front contact solar cell where the Al 2 O 3 which is the passivation also serves as a dopant source for emitter formation A front contact solar cell, Where the Al 2 O 3 is deposited using ALD, APCVD, or PECVD after dopant sources have been stripped. Where combination of Al 2 O 3 and SIN serve as the ARC
[0100] A front contact solar cell where both selective and non-selective emitter PERC designs are combined with the non-sunny (rear) interface consisting of silicon, wide-bandgap semiconductor, and metal.
[0101] For a non-bifacial structure having a multi-layer dielectric stack:
A front contact solar cell where the non-sunny (rear) interface consists of silicon, a multi-layer dielectric stack including a wide-bandgap semiconductor, and a metal
a. Where the stack for n-type is Al 2 O 3 /TiO x /Al or Al 2 O 3 /TiO x /Ti
A front contact solar cell where the front (sunny-side) emitter passivation is Al 2 O 3 in combination with the rear (non-sunny side) interface consisting of silicon, a multi-layer dielectric stack including a wide-bandgap semiconductor, and a metal.
a. Where the stack for n-type is Al 2 O 3 /TiO x /Al or Al 2 O 3 /TiO x /Ti
A front contact solar cell where both selective and non-selective emitter PERC designs are combined with the non-sunny (rear) interface consisting of silicon, a multi-layer dielectric stack including a wide-bandgap semiconductor, and metal.
a. Where the stack for n-type is Al 2 O 3 /TiO x /Al or Al 2 O 3 /TiO x /Ti
[0108] For a bifacial structure having a single stack (for n-type and p-type silicon):
A bifacial solar cell (not limited to PERC) where the bifaciality is achieved by growing a wide band gap semiconductor and ITO in-situ in an ALD reactor and using a patterned metal on top. A bifacial solar cell where the rear side (non-sunny side) stack consists of silicon semi-conductor, a wide bandgap semiconductor/dielectric such as TiO x on n-type and NiO on p-type, and Al 2 O 3 for both n and p-type, and an optional transparent conducting oxide (TCO) such as ITO, and a patterned metal.
a. Where the TCO layer on the rear side (non-sunny side) is optional, but the patterned metal is a must. b. Where the TCO layer, when present is ITO and is optimized to serve as an ARC. c. Where the ITO layer, when present, is deposited in-situ along with the wide bandgap semiconductor in the ALD reactor d. Where the ITO layer, when present, is deposited separately using a different deposition scheme such as PVD. e. Where the patterned metal is a metal with a vacuum workfunction close to the conduction band edge of silicon for n-type silicon
i. Where this metal is aluminum deposited using PVD, screen print, or other means ii. Where this metal is titanium deposited using PVD
f. Where the patterned metal is a metal with a vacuum workfunction close to the conduction band edge of silicon for the p-type silicon
i. Where this metal is nickel deposited using PVD, inkjet, or other means.
[0120] A bifacial solar cell where the rear side (non-sunny side) stack consists of silicon semi-conductor, a multi-layer dielectric stack with a wide bandgap semiconductor/dielectric such as TiO x on n-type and NiO on p-type along with thin Al 2 O 3 , and an optional transparent conducting oxide (TCO) such as ITO, and a patterned metal.
[0121] The foregoing description of the exemplary embodiments is provided to enable any person skilled in the art to make or use the claimed subject matter. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without the use of the innovative faculty. Thus, the claimed subject matter is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | 4y
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FIELD OF THE INVENTION
The present invention relates generally to light ballasts and more particularly to a method and system for providing a high resolution dimmable light ballast.
BACKGROUND OF THE INVENTION
FIG. 1 is a block diagram of a dimmable light ballast system 10 . The system 10 includes a microcontroller 12 which typically controls a dimmable light ballast 16 via its controller 11 and a timer structure 14 . Electronic dimmable ballasts are controlled by on/off pulses. Varying the pulse lengths up and down controls the brightness of the light. A pulse is typically generated by dividing a frequency base through a series of fixed prescalers and/or programmable dividers. High resolution frequency control in dimmable light ballasts is conventionally addressed by using a low frequency digital part which is connected to analog components. This combination of elements converts low frequency pulses to a series of high frequency pulses. This method is referred to as indirect PWM control.
Light ballasts are utilized in a variety of applications. Oftentimes, these light ballasts are dimmable. However, it is important that the dimming resolution be of high resolution to allow for a variety of settings of light.
The resolution for a traditional timer frequency divider is:
f
GEN
=
f
BASE
n
(
1
)
The human eye is sensitive to variations of the light level, and frequency changes must be small for the eye not to notice. The frequency can be changed with a resolution expressed by equation 2 below.
Δ
f
GEN
=
f
BASE
n
-
1
-
f
BASE
n
=
f
BASE
n
*
(
n
-
1
)
(
2
)
For a high resolution light ballast, the target for frequency change is less than 50 Hz. At 80 kHz frequency and 50 Hz resolution the divider value becomes:
Δ
f
GEN
≤
f
GEN
*
n
n
*
(
n
-
1
)
(
3
)
Solving equation (3) for a frequency of 80 kHz and a resolution of 50 Hz gives n=1600. Inserting n=1600 gives a frequency base of 80 Hz*1600=128 MHz which is a very high frequency.
Today designs are using lower frequency timer outputs, which are multiplied externally to higher frequencies, often using analog technology, i.e., an indirect method is used to control the pulse width. These designs therefore are controlled by some type of timer structure. There are a variety of known timer structures. Some of them are described in summary fashion below.
1. Advanced Timer Structures
Advanced timer structures have previously been used in microcontrollers to allow use of multiple frequencies. Some typical methods include:
a. Timer with Down-counter and Reload Registers
The counter counts down until it reaches zero. It then reloads from a reload register, toggles an output and interrupt a processor, which can load the reload register with a different value. For 50% duty cycle, a single register per pulse is needed. If pulse width modulation is needed, two reload registers per pulse are needed. Very few processors support interrupt rates at the frequencies used in ballasts. This type of timer is very common, both in low and high-end controllers.
b. Timer with Down-counter and Multiple Reload Registers
A variation of the counter above uses multiple reload registers. Typically an additional set is used. The use of this structure is mainly to allow a frequency to change as a result of an external event, and will only allow a single change, without processor intervention.
Again, this results in very high interrupt rates. An additional counter can be connected allowing the frequency to change only after a number of pulses has been generated.
c. Timer Complex with Chain Mode
To achieve the average frequency improvement to 1/16 th of that of a single frequency, 16 or 32 reload registers are needed. Such implementations are available in advanced processors. The timer complex may have a “chain” mode, where a timer controls an output on the microcontroller. It operates for a certain time, but when a specific event occurs, it will forward control of output to a different timer which is “chained” to the first timer. The Motorola TPU Timer Processing Unit is a typical example of such a timer. The TPU is implemented using a programmable controller and uses significant chip area.
d. Timer with Down-counter and Reload Registers and DMA Support
Some processors can maintain the reload registers in a table in an inexpensive SRAM. When the counter is loaded from the reload register, a DMA request is generated, and the DMA controller will load the reload register from the table. The DMA can support a circular buffer structure where the index of the table is automatically reset to the start of table when the end of table is reached. While this implementation is less expensive than the timer complex, it is still fairly expensive, and is not good for low cost implementation. This implementation is typically used for motor control.
e. Serial Interfaces
Serial communications peripherals with bit rates at the base frequency can be used to generate any bit sequence, and can obviously be used to emulate a timer. This relies on storing the bit pattern in an internal buffer and is much more expensive than the timer structure, making it unattractive for low cost implementation.
f. Timer with Up/Down-counter and Compare Registers
A timer structure similar to the down counter with reload is the counter with compare register. The timer counts up/down until a programmable value is reached. It then either reloads with a fixed value or from a small set of fixed values, or changes direction. Both structures are inherently relying on large blocks of external hardware in the form of processors, multiple reload registers or DMA support to change the frequency.
g. PWM Timer with Dithering Support
Some low-end microcontrollers implement Digital to Analog converters using a pulse width modulated timer. The output is filtered through an analog filter, and the output voltage is depending on the pulse width of the timer (ratio tHIGH/(tHIGH+tLOW). By varying the pulse width, the output voltage can be changed. The cost of the analog filter is depending on the PWM frequency and it is desirable to avoid lower frequencies. The problem is similar to that of the ballast, since dividing a base frequency with a programmable value generates the PWM frequency.
To increase the resolution of the D/A converter, some microcontrollers (including those focusing on CRT monitors) use dithering or flank width modulation. The PWM pulses are divided into frames of longer or shorter than the nominal value in a pulse width register. The “average” pulse length is thus increased or decreased by 1/nth of a clock pulse every time a flank is modulated. The PWM frequency is not changed to avoid problems with the analog filter.
h. Clock Generator with Added Noise
Some clock generators used to provide a system clock for an electronic system vary the frequency over a short frequency interval to divide the energy over a larger frequency spectrum. This function is mainly there to reduce EMI, and chips implementing this normally does not allow controlling the variation of the clock frequency in a predictable manner, and generally lack all other features necessary to implement ballast control.
Accordingly, all of the above implementations either require complex circuitry and typically require microcontrol. The present invention addresses such a need.
SUMMARY OF THE INVENTION
A microcontroller or state machine controls a light ballast utilizing a timer structure. The microcontroller can program the timer structure to generate pulses where the “average” frequency of a series of pulses can be varied with higher resolution than the frequency of a single pulse. This variation can occur without further microcontroller/state machine intervention. The pulses are used to control the on and/or off time of the light. The timer can be configured to modulate the outputs fast enough to ensure that the light does not appear to flicker to the human eye by limiting the number of pulses in a frame and by increasing the number of times the frequency shift occurs compared to the obvious implementation.
The present invention relies on the fact that the human eye is not capable of detecting small frequency changes in high frequency signals and therefore uses pulses of two or more frequencies where the frequencies are close together. The average frequency can then be varied at much higher resolution than any single frequency.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a dimmable light ballast system.
FIG. 2 is a block diagram of a timer for providing controlling a light emitting device in accordance with the present invention.
FIG. 3 is a Table 2 which illustrates the operation of another timer structure which includes an adder which increases or decreases by a programmable value for each increase or decrease in the light intensity of the light ballast.
DETAILED DESCRIPTION
The present invention relates generally to light ballasts and more particularly to a method and system for providing a high resolution dimmable light ballast. The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiment and the generic principles and features described herein will be readily apparent to those skilled in the art. Thus, the present invention is not intended to be limited to the embodiment shown but is to be accorded the widest scope consistent with the principles and features described herein.
Electronic dimmable ballasts are controlled by on/off pulses. Varying the pulse lengths up and down controls the brightness of the light. A pulse is typically generated by dividing a frequency base through a series of fixed prescalers and/or programmable dividers.
A designer of a ballast typically chooses to use a variable frequency with a fixed ratio of on time and off time (frequency control), or of a mixed frequency where the ratio of on time to off-time can be varied (PWM control). A fixture of the two where the frequency and the ratio can be varied is conceivable. A system and method in accordance with the present invention is applicable in all three variations, but will be explained using the frequency paradigm where the pulse length is varied by changing the frequency.
The objective of the present invention is:
1. To reduce the base frequency required achieving a certain resolution at a certain target frequency to a frequency lower than that required by a normal frequency divider.
2. To use direct PWM/frequency control allowing integration of the functionality into an inexpensive microcontroller using a standard semiconductor process.
3. To reduce the processing requirement to allow implementation using low cost 8 bit controllers. The invention relies on the fact that the human eye is not capable of detecting small frequency changes in high frequency signals and uses pulses of two or more frequencies. The average frequency can be varied at much higher resolution than any single frequency.
A system and method in accordance with the present invention comprises a timer capable of generating a sequence of on-time and off-time pulses where the on and/or off-time pulse lengths can be programmed to continuously switch between at least two different values at a particular resolution within a time period short enough to avoid flickering in a dimmable ballast light system. To describe the features of the present invention in more detail refer now to the following discussion in conjunction with the accompanying figures.
FIG. 2 is a block diagram of a timer structure 140 in accordance with the present invention. The timer structure receives a clock signal that is fed into a first counter (PWM) 142 . In this embodiment, two reload registers 144 are utilized but a single register or more could be utilized and this would be within the spirit and scope of the present invention. Each of the reload registers 144 may include a different pulse length value. In a preferred embodiment a security mechanism 153 is utilized to deassert on-time signals when error conditions are detected. During operation, the first counter 142 counts down until zero is reached and then it restarts by reloading from one of the reload registers.
When the value in counter 142 is less than a predetermined value in a compare register 147 indicating that the resolution can not be changed the output from the comparator is provided directly to the output decision logic (PWMOUT) 152 of the pulse width modulator, which sets/clears the PWM signal and its inverse respecting requirements for non-stop.
Whenever the first counter 142 has reached a predetermined value indicating one cycle is completed (i.e., the counter 142 has reached zero), a second counter 146 (frame) is incremented. When the contents of the counter 142 are equal to the contents of the register 147 the contents of a “dither” register 148 via comparator 150 to determine the ratio of first counter 142 pulses that should be extended by one clock cycle for a particular resolution. For example if a frame is 4 bits wide, between 0 to 15 pulses can be extended in a 16 pulse frame.
If the comparison was performed normally only the first pulses would be extended (I.e., if 3 out of 16 pulses should be extended, pulses 0 . . . 2 would be extended and pulses 3 . 15 would not be extended). However, to spread the pulses out, the counter 146 value is bit reversed before the comparison. An example of a normal comparison versus a bit reversed comparison is shown in Table 1.
TABLE 1
pulse
normal
<=2
bitreversed
<=2
0
0000
1
->
0000
1
1
0001
1
->
1000
0
2
0010
1
->
0100
0
3
0011
0
->
1100
0
4
0100
0
->
0010
1
5
0101
0
->
1010
0
6
0110
0
->
0110
0
7
0111
0
->
1110
0
8
1000
0
->
0001
1
9
1001
0
->
1001
0
10
1010
0
->
0101
0
11
1011
0
->
1101
0
12
1100
0
->
0011
0
13
1101
0
->
1011
0
14
1110
0
->
0111
0
15
1111
0
->
1111
0
As is seen with the normal comparison, the first three pulses get a “match”. With the bit reversed comparison, the pulses 0,4 and 8 get a match.
An optimal distribution is reached by using differential data synthesis (DDS), where utilizing a frame size of 16, 16/n would be added to the number. Accordingly, where n=3 16/3 would be added to the number. The algorithm for implementing DDS would require more logic and be relatively expensive utilizing present day technology. However, one of ordinary skill in the art recognizes that there may be a time that this type of algorithm may require significantly less die area and could be readily utilized in such an application.
FIG. 3 is a Table 2 which illustrates the operation of the timer structure which includes an adder which increases or decreases by n for each increase or decrease in the light intensity of the light ballast. The system would operate in accordance with the following algorithm.
x=0
adder=n
loop
x=x+adder;
//Result in Column 1, Table 2
0 if (x >- framesize) then;
x=x = framesize
//Result in Column 2 Table T
extend=1;
//Result in Column 2, Table 2
else
extend=0;
end if
end loop;
As is seen in Column 3, as the frequency increases, the number of pulses that should extended by one cycle increases in a distributed fashion.
Embodiments
In a preferred implementation, the control mechanism allows the average pulse width over a sequence of pulses to be programmed without specifying a value for each and every pulse.
In a preferred implementation, only two frequencies are used, the dividers only differ by one. f1=f/n, f2=f(n−1), allowing the control mechanism to choose between extending a pulse by one clock or not, instead or providing two unrelated values.
In a preferred implementation, the number of cycles in a frame is fixed, and the number of cycles to be extended is programmable.
In a less desirable implementation, the number of extended cycles is fixed, and the number of cycles in a frame is programmable.
In a less desirable implementation, the number of extended cycles and the number of cycles per frame are both programmable.
In a preferred implementation, the number of pulses to be extended in each frame is supplied as a number to the timer.
In a preferred implementation, the pulse-width is in the upper parts of a register, while the number of pulses to be extended is in the lower part of the register. This treats the average value as a fractional number.
In a less desirable implementation, the number of pulses to be extended is in the upper part of a register and the pulse-width is in the lower part of the register. This simplifies the silicon implementation allowing a timer with a long time period to be used in several modes without adding too much logic.
In a less desirable implementation, the pulse width and the information regarding which pulses are to be extended is separated into two or more registers.
It is to be noted, that when a register is wider than the data-width of the micro-controller it can take several memory cycles to access a register.
In a less desirable implementation, there is a register or set of registers containing one or more bits for each pulse or for a group of pulses in the frame, which is used to determine whether a pulse should have a certain pulse length or another pulse length.
Distribution of Pulses
In a preferred implementation, the timer maintains a frame-counter, which is updated with every pulse or group of pulses. It has a dual purpose, the first purpose is to introduce a mechanism to detect the end of a frame and start a new one, and the second purpose is to allow a mechanism to decide whether to extend a pulse or not.
In a preferred implementation, the frame-counter counts up or down in a linear fashion.
In a less desirable implementation, the frame-counter counts in a non-linear fashion. An example is a “Gray” counter.
In a less desirable implementation, the frame-counter directly is compared to the number of pulses to be extended, and if the frame-counter is lower or equal to the number of pulses, the current pulse is extended.
In a preferred implementation, the frame-counter and/or the number of pulses are scrambled through bit reversal to binary distribute the number of pulses.
In a less desirable implementation, DDS (Digital Differential Synthesis) algorithms are used to distribute the pulses. It will distribute the pulses more evenly, but will cost more logic.
In a less desirable implementation, the pulses are distributed using a random fashion using a pseudo-random generator.
Counter
The pulse-length functionality can be implemented using a down counter, an up counter or an up-down counter.
The down-counter approach compares the counter with an end value, which is normally zero. When the end value is reached, the counter is reloaded from one of a set of reload registers.
The up-counter approach compares the counter with a set of compare registers. When a compare match is detected, the timer can toggle an I/O pin, or start a new cycle and maybe generate an interrupt.
The up-down counter approach counts up until a compare-match occurs, which may or may not be programmable. It then counts down until zero, before it restarts counting up. A compare register will determine if the counter is below, equal or above the compare register and a match can force the setting or resetting of a pin.
Compare registers can be attached to the counters, to force events in the middle of a counter cycle.
In a preferred implementation, the down-counter approach is used.
Extending a Pulse
In a preferred implementation, a pulse can be extended by stopping the counter temporarily or by manipulating a reload or a compare register value.
The reload/compare values can contain the on time, the off time or a combination of both. The timer is normally connected to two outputs allowing direct control of the output pulses. The reload/compare values can contain times for either one or both outputs. Either of the on/off-time cycles or both can be modulated.
In a less desirable implementation, the timer block provides a single output which can be used by an external circuit to drive a half-bridge or full-bridge.
Dead Time
In a preferred implementation there are two outputs with programmable “dead-time” between the on time of one output and the on time of the other output.
In a preferred implementation, there are two outputs with inverted outputs, allowing direct drive of an inverting transistor between the part containing the invention and the power transistor (typically a FET transistor).
In a preferred implementation, the micro-controller contains a fuse setting which sets the initial state of the output pin to a value, which disables any power transistors in the system.
In a preferred implementation, external hardware (i.e., pullup/pulldown resistors) set the initial state of the outputs.
Number of Reload/Compare Registers
In a preferred implementation, the registers have shadow registers, which can be selected instead of the “normal” registers to handle error conditions. Both normal and shadow registers can support pulse extension.
In a preferred implementation, there are security mechanisms that can deassert the on-time signals when error conditions are detected. ( FIG. 2 , 153 .)
In a preferred implementation, the error circuitry may either interrupt the microcontroller, which can subsequently reprogram the timer block, and/or it may directly change the timer frequency before a possible interrupt using values in shadow registers.
Advantages
1. A system and method in accordance with the present invention uses direct control of a pulse width (PWM), making it more cost effective/using less board space than previous indirect control solutions using analog PWM circuits for the high frequency.
2. A system and method in accordance with invention implements a frequency generator using a relatively small base frequency, which can be implemented in low cost controllers. Low frequency reduces the power consumption compared to a pure frequency divider, and is advantageous for other reasons including EMI considerations.
3. A system and method in accordance with the present invention combines low base frequency with high resolution, making it more attractive for dimmable ballasts.
4. A system and method in accordance with the present invention can be implemented in a very small die area compared to timer complexes, DMA driven timers or timers with multiple reload registers, making it possible to reduce the cost of a microcontroller for ballasts.
Although the present invention has been described in accordance with the embodiments shown, one of ordinary skill in the art will readily recognize that there could be variations to the embodiments and those variations would be within the spirit and scope of the present invention. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims. An example of such a modification is a mechanism to guarantee “dead time” between two different outputs which ensures that both FET transistors, in a half bridge and not turned on at the same time. | 4y
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/817,306 filed on Apr. 29, 2013 and entitled “3D-Motion Gesture/Proximity Detection Module Sensor (MGPS)”, the contents of which are incorporated herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a motion sensing device, and more particularly, to a motion sensing device realized by a wafer level lens.
2. Description of the Prior Art
With the scientific and technological advancement, computer systems are viewed as necessities for ordinary people in their daily lives, from traditional functions, such as word processing and program executing, to modern multimedia processing, and computer games, etc. Thus, technology of the input apparatus also has improved.
A pointing device is utilized for transforming motions of a user into signals via a motion sensor capable of sensing a motion trace for an electronic device having computing capacity, so as to control the movement of graphical cursers or pointers on display screens, to select objects on display screens with a graphical user interface, and to perform control functions displayed on the screen, allowing the user direct interaction with the computer system. Thus, how to realize the motion sensor with high accuracy becomes a topic to be discussed.
SUMMARY OF THE INVENTION
In order to solve the above problem, the present invention provides a motion sensing device realized by a wafer level lens.
The present invention discloses a motion sensing device for sensing infrared rays, comprising a substrate; an optical module, comprising a first spacer layer, coupled to the substrate; a first glass layer, formed on the first spacer layer; a second spacer layer, formed on the first glass layer; a second glass layer, formed on the second spacer layer; a third spacer layer, formed on the second glass layer; a first lens, bonding on a first side of the second glass layer; and a second layer, bonding on a second side relative to the first side of the second glass layer; and a coating layer, covered on the optical layer for shielding the infrared rays, wherein the coating layer does not cover the first lens.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross section view of a motion sensing device according to an embodiment of the present invention.
FIG. 2 is a flow chart of a packaging method according to an embodiment of the present invention.
FIG. 3 is a flow chart of another packaging method according to an embodiment of the present invention.
DETAILED DESCRIPTION
Please refer to FIG. 1 , which is across section view of a motion sensing device 10 according to an embodiment of the present invention. The motion sensing device 10 is utilized for sensing infrared rays, to detect the moving traces and the motions of external objects. As shown in FIG. 1 , the motion sensing device 10 comprises a substrate 100 , an optical module 102 and a coating layer 104 . The substrate 100 comprises an optical sensing layer 106 and a transmission layer 108 , for sensing the light and accordingly outputting corresponded sensing signal. The optical layer 102 comprises spacer layers 110 - 114 , glass layers 116 and 118 and lens 120 and 122 , for filtering the light emitting to the substrate 100 such that the light emitting to the substrate 100 only comprises light with a specific wavelength (e.g. the wavelength of the infrared rays). For example, the optical module 102 may be a wafer level lens used for receiving the infrared rays. The coating layer 104 covers the optical layer 102 , for preventing additional infrared rays from emitting to the substrate 100 . Please note that, the coating layer 104 does not cover the lens 120 (i.e. does not cover the path of light emits to the substrate 100 ), for ensuring the motion sensing device 10 operates normally. As a result, the motion sensing device 10 for sensing the moving traces and the motions of the external objects can be realized by the wafer level lens. The motion sensing device 10 equipped with micro volume can be achieved.
In detail, the optical sensing layer 106 comprises a sensing unit SEN for sensing the light filter by the optical module 102 and outputting the corresponded sensing signal. According to different applications and design concepts, the method of configuring the sensing unit SEN on the substrate 100 can be appropriately changed. For example, the sensing unit SEN may be configured on the substrate 100 via a chip scale package (CSP) method, printed circuit board method or a lead frame method, and is not limited herein. In this embodiment, the transmission interface layer 108 comprises a ball grid array (BGA) (i.e. realized in the packaging technology of the ball grid array). Via a wafer-level chip scale packaging method with a through-silicon via technique, the sensing signal generated by optical sensing layer 106 can be transmitted to the external circuit through the transmission interface layer 108 , for performing corresponded calculating processes.
In addition, the optical module 102 is coupled (e.g. bonded) to the substrate 100 through the spacer layer 110 . For example, the spacer layer 110 may be glue or paint, and is not limited herein. The glass layer 116 is configured on the spacer layer 110 , for protecting the sensing unit SEN. The spacer 112 is configured between the glass layers 116 and 118 , for generating a space 124 . In this embodiment, the materials of the spacer layer 112 may comprise glass. The glass layer 118 is configured on the spacer layer 112 as the substrate of the lens 120 and 122 . The spacer layer 114 is configured on the glass layer 118 and forms an opening 126 . The lens 120 is configured in the opening 126 and is coupled (e.g. bonded) to a side of the glass layer 118 (e.g. the top side of the glass layer 118 ) via a translucent glue, such as a silicone, an Epoxy, and an Ultraviolet light (UV) Curable Adhesive. Similarly, the lens 122 is configured in the space 124 and is coupled (e.g. bonded) to another side of the glass layer 118 (e.g. the bottom side of the glass layer 118 ) via the translucent glue.
Finally, since the operations of the sensing unit SEN senses the motions of the objects is achieved via detecting the infrared rays, the sensing unit SEN is sensitive to the variations of infrared rays in the surrounding environment. In such a condition, the coating layer equipped with the function of shielding the infrared rays is needed to cover the optical module 102 , for shielding the infrared rays of the specific wavelength range, so as to avoid affecting the sensing result of the sensing unit SEN. Please note that, the coating layer 104 does not cover the lens 120 , for ensuring the path of the infrared rays emits to the sensing unit SEN. In addition, the motion sensing device 10 may further comprise an infrared ray emitting unit (not shown in FIG. 1 ), for emitting the infrared rays capable of passing through the lens 120 and 122 and being sensed by the sensing unit SEN. As a result, via the coating layer 104 absorbing the additional infrared rays, the motion sensing device 10 can receive the infrared rays emitted by the infrared ray emitting unit by the optical module 102 (e.g. the wafer level lens. The functions of sensing the moving traces and motions of the objects can be accordingly achieved, therefore.
Noticeably, the above embodiments provide a motion sensing device realized by the wafer level lens, so as to reduce the manufacture cost and increase the production efficiency via the wafer level manufacturing technology. According to different applications and design concepts, those with ordinary skill in the art may observe appropriate alternations and modifications. For example, the wavelength of the light received by the sensing unit SEN for performing the operations of sensing the moving traces and motions of the objects can be altered to different wavelength ranges, such as the wavelength ranges of the UV and the visible light. Note that, when the wavelength range of the light received by the sensing unit SEN changes, the wavelength range of the light shielded by the coating layer 104 needs to be accordingly altered for avoiding affecting the sensing result of the sensing unit SEN.
In the above embodiments, the single motion device is described for illustrating the structure and the packaging method. In general, when producing the packages of the motion sensing device, the entire packaging materials are configured layer by layer for generating multiple packages at the same time. Then, the multiple packages are sawed for acquiring multiple separate packages. According to different applications, the motion sensing device can be packaged by different packaging methods. For example, the substrate 100 and the optical module 102 can be realized in different wafers. Via wafer bonding, the substrate 100 and the plurality of optical module 102 configured on different wafers can be bonded. Next, the coating layer 104 is formed on each optical module 102 via the package coating. Finally, the single motion sensing device 10 can be acquired after the package sawing process.
On the other hand, the step of bonding the substrate 100 and the plurality of optical modules 102 configured on different wafer can be appropriately modified according to different applications. In an embodiment, the plurality of optical modules 102 configured on the wafer is cut for acquiring the plurality of separate optical modules 102 . Each of the optical modules 102 is bonded to the substrate 100 configured on the wafer, and then performing the follow-up processes, such as the coating process and the sawing process. According to the above steps, the single motion sensing device 10 also can be acquired.
The packaging method of the motion sensing device abovementioned can be summarized into a packaging method 20 , as shown in FIG. 2 . The packaging method 20 comprises the following steps:
Step 200 : Start.
Step 202 : Perform a wafer bonding process, for bonding a plurality of optical modules on a first wafer and a substrate on a second wafer.
Step 204 : Perform a package coating process, for forming a coating layer, used for absorbing infrared rays, on the plurality of optical modules.
Step 206 : Perform a package sawing process.
Step 208 : End.
According to the packaging method 20 , a plurality of optical modules on a first wafer can be bonded to a substrate on a second wafer. Next, a coating layer can be formed on each optical module for absorbing the infrared rays, via performing a package coating process. After performing a package sawing process, the single motion sensing device can be acquired.
The packaging method of the motion sensing device abovementioned can be further summarized into another packaging method 30 , as shown in FIG. 3 . The packaging method 30 comprises the following steps:
Step 300 : Start.
Step 302 : Perform a package sawing process on a plurality of optical modules configured on a first wafer, for acquiring separate optical modules.
Step 304 : Bond the separate optical modules to a substrate configured on a second wafer.
Step 306 : Perform a package coating process, for forming a coating layer, used for absorbing infrared rays, on the plurality of optical modules.
Step 308 : Perform a package sawing process.
Step 310 : End.
According to the packaging method 30 , the plurality of optical modules configured on the first wafer is sawed into separate optical modules (e.g. wafer level lens) and then the separate optical modules are bonded to the substrate configured on the second wafer. Similar to the steps 204 and 206 of the packaging method 20 , after performing the package coating process and the package sawing process, the single motion sensing device is therefore acquired.
To sum up, the above embodiments utilize the wafer level lens to realize motion sensing device. The manufacture cost can be reduced and the production efficiency can be improved via the wafer level manufacturing technology. Moreover, the motion sensing device of the above embodiments can be packaged via different packaging methods according to different applications and design concepts.
Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims. | 4y
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BACKGROUND OF THE INVENTION
The present invention relates to reinforced polyethylene plastic fittings suitable for use in piping systems for the transport of fluid under pressure.
Heretofore, plastic pipe fittings, such as tees, elbows and couplings, have been patterned after their metal counterparts in that they have been essentially uniform in wall thickness throughout the body of the fitting. This can create problems where the plastic fitting needs to have a higher pressure rating than the pipeline-main in order to withstand internal pressure. Several methods have been utilized to increase the pressure rating of the plastic fittings. One such method is fabricating the fitting out of heavier pipe having a lower SDR (Standard Dimension Ratio or the ratio of the outer pipe diameter to the wall thickness of the pipe) than the pipeline to which the fitting is to be attached. However, such a method does not provide a fitting with an inside diameter bore equal to that of the pipeline-main, nor does it provide the fitting with ends of the same size and SDR to match the pipeline-main for purposes of connection to the pipeline-main by means of butt-fusion of ends to the pipeline-main.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide for reinforced fittings which have inside diameter bores of diameter equal to that of the pipeline-mains to which they will be attached.
It is a further object of this invention to provide reinforced pipeline fittings which have butt-ends of the same size and SDR to match to the pipeline-main for purposes of butt-fusion of matching ends.
In one aspect of the present invention, there is provided a reinforced pipe fitting comprising an inner tubular member and an outer tubular member wherein said outer tubular member surrounds said inner tubular member in an interference fit.
In another aspect of the present invention, there is provided a process for manufacturing reinforced pipe fittings comprising placing an outer tubular member around an inner tubular member in an interference fit. After the tubular members have been joined by interference fitting, at least the outer tubular member is selectively cut to produce cut pieces and the cut pieces are butt-fused together to form the desired shape of the fitting.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial representation of an interference fit between two pipe lengths with the dotted line illustrating a cut to be made in the resulting dual pipe length.
FIG. 2 is a pictorial representation of an interference fit between two pipe lengths with the dotted line illustrating a cut to be made in the resulting dual pipe length.
FIG. 3 is a pictorial representation of a resulting T-fitting produced from the cut dual pipe length of FIGS. 1 and 2.
FIG. 4 is a pictorial representation of an interference fit between two pipe lengths with the dotted line illustrating a cut to be made in the resulting dual pipe length.
FIG. 5 is a pictorial representation of the resulting elbow fitting produced from the cut dual pipe length of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
The pipe fittings, pipeline-mains and pipes referred to herein are comprised of polyethylene and/or polyethylene copolymers and preferably of high density polyethylene and/or high density polyethylene copolymers.
The reinforced pipe fittings produced according to this invention comprise an inner pipe, or tubular member, and an outer pipe, or tubular member. The outer pipe or tubular member is fitted over the inner pipe in an interference fit such that it surrounds and encases the circumference of the inner pipe. "Interference fit" is used herein to refer to a negative fit, necessitating expansion in one mating part or contraction in the other mating part during assembly. Generally such expansion or contraction can be accomplished by heating or cooling the outer pipe or inner pipe respectively, or such expansion or contraction can be accomplished by applying sufficient force to cause expansion in the outer pipe or contraction in the inner pipe.
The inner pipe will be of the same size and SDR as the pipeline-main with which the fitting is to be mated. Also, it is preferred that the inner pipe will be of greater length than the outer pipe so that upon application of the fitting at least one length of inner pipe will be available which is not surrounded by the outer pipe so that such length is available for mating with the pipeline-main. The outer pipe should have an inner diameter which will allow an interference fit with the outer surface of the inner pipe.
Once the inner pipe and outer pipe are mated in an interference fit, the pipes are cut into pieces from which the pipe fittings can be constructed. The pieces are then butt-fused face to face to form the fitting. By butt-fusing, it is meant that a localized heat is applied to a face of each of two of the pieces in order to melt or soften the polyethylene at the face. Then the heated faces are placed in contact and allowed to cool under sufficient pressure to produce a weld seam along the faces so that the two pieces are joined as one with a zero-leak-rate joint.
Better understanding of the invention can be gained by reference to the Figures. FIGS. 1-3 represent a first embodiment of the invention and FIGS. 4 and 5 represent a second embodiment.
Referring now to the embodiment illustrated in FIGS. 1-3, the formation of the plastic pipe T-fitting is shown. FIG. 1 shows an outer plastic pipe 1, or outer tubular member, which is mated to an inner pipe 3, or inner tubular member, in an interference fit such that outer pipe 1 surrounds inner pipe 3 so as to form dual pipe length 5. The inner pipe and outer pipe are positioned so that a first length 7 of inner pipe 3 and a second length 9 of inner pipe 3 extend out and from the portion of inner pipe 3 which is surrounded by inner pipe 1. First length 7 and second length 9 are of sufficient length to be connected to the pipeline-main by butt-fusion techniques. After the inner pipe and outer pipe have been mated in an interference fit, an aperture is cut in the dual pipe length as illustrated by dotted lines 11 and 12.
In FIG. 2, there is illustrated an interference fit between an outer pipe 13 and inner pipe 15 to create a dual pipe length 17. Dual pipe length 17 is similar to dual pipe length 5 except that dual pipe length 17 has only a first length 19 of pipe extending out from the portion of inner pipe 15 surrounded by outer pipe 13. Both outer pipe 13 and inner pipe 15 have an end located at terminus 21. After the dual pipe length 17 is formed it is cut as illustrated by dotted line 23 and 25 in order that terminus 21 is formed into a shape which is matable with the periphery of the aperture formed by cutting dual pipe length 5 along dotted lines 11 and 12.
Referring now to FIG. 3, a tee fitting produced by mating the cut terminus 21 of dual pipe length 17 with the periphery of the aperture in dual pipe length 5 can be seen. Dual pipe length 17 and dual pipe length 5 are butt-fused during mating along seam 27 to form fluid-tight joints.
Referring now to FIGS. 4 and 5, a second embodiment of the invention can be seen. FIGS. 4 and 5 illustrate the formation of an elbow fitting by the process of the present invention. FIG. 4 illustrates an outer pipe 31 which has been interference fitted with an inner pipe 33 to form a dual pipe length 35. Dual pipe length 35 has a first length 37 and a second length 39 extending out from the area where the outer pipe 31 surrounds inner pipe 33. Dual pipe length 35 is cut in accordance with dotted line 41 to create pipe pieces 43, 45, 47, 49 and 51. The pieces 43-51 are then rearranged by rotating pieces 45 and 49 180° and butt-fused together to create the elbow fitting illustrated in FIG. 5. The pieces are butt-fused together to create fluid-tight joints 53.
Optionally, cuts 41 can be only through outer pipe 31 in which case, after cuts 41 have been made, inner pipe 33 is bent or deformed into the desired elbow, or L-shape. After inner pipe 33 has been bent into the desired shape, the pieces of outer pipe 45 and 49 are then rotated 180° into the appropriate configuration and butt-welded together in order to form seam 53.
The resulting fittings from the techniques described above have an inner bore diameter which is equal to that of the pipeline-main and ends of the same size and SDR to match the pipeline-main for purposes of connecting the fitting to the pipeline-main by butt-fusing of matching ends.
Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than specifically described. | 4y
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This application claims priority from U.S. Provisional Application No. 60/263,860, titled “Reinforcing Bar Connection and Method,” filed Jan. 23, 2001.
TECHNICAL FIELD
This invention relates generally as indicated to a reinforcing bar connection, and more particularly to a high strength reinforcing bar splice which provides not only high tensile and compressive strengths, but also has the dynamic and fatigue characteristics to qualify as a Type 2 coupler approved for all United States earthquake zones. The invention also relates to a method of making the connection.
BACKGROUND OF THE INVENTION
In steel reinforced concrete construction, there are generally three types of splices or connections; namely lap splices; mechanical splices; and welding. Probably the most common is the lap splice where two bar ends are lapped side-by-side and wire tied together. The bar ends are of course axially offset which creates design problems, and eccentric loading whether compressive or tensile from bar-to-bar. Welding is suitable for some bar steels but not for others and the heat may actually weaken some bars. Done correctly, it requires great skill and is expensive. Mechanical splices normally require a bar end preparation or treatment such as threading, upsetting or both. They also may require careful torquing. Such mechanical splices don't necessarily have high compressive and tensile strength, nor can they necessarily qualify as a Type 2 mechanical connection where a minimum of five couplers must pass the cyclic testing procedure to qualify as a Type 2 splice in all United States earthquake zones.
Accordingly, it would be desirable to have a high strength coupler which will qualify as a Type 2 coupler and yet which is easy to assemble and join in the field and which does not require bar end preparation or torquing in the assembly process. It would also be desirable to have a coupler which could be assembled initially simply by sticking a bar end in an end of a coupler sleeve or by placing a coupler sleeve on a bar end.
SUMMARY OF THE INVENTION
A reinforcing bar connection for concrete construction utilizes a contractible jaw or assembly which is closed around aligned bar ends to form the joint and tightly grip the bars. The jaw assembly is closed from each axial end to constrict around and bridge the ends of end-to-end reinforcing bars. The jaws of the assembly have teeth which bite into the ends of the bar. The assembly is constricted by forcing self-locking taper sleeves or collars over each end which hold the jaw constricted locking the bars together. The teeth are designed to bite into the ribs or projecting deformations on the surface of the bar which forms the overall diameter, but not bite into the core or nominal diameter of the bar. In this manner, the splice does not affect the fatigue or ultimate strength properties of the bar while providing a low slip connection. The jaw segments may be held assembled by a frangible plastic frame. The configuration of the jaws limits the contraction and precludes undue penetration of the bar by the teeth. The connection or splice has high tensile and compressive strength and will pass the dynamic cycling and/or fatigue requirements to qualify as a Type 2 coupler. No bar end preparation or torque application is required to make the coupling. In the method, the closing and locking occur concurrently with a simplified tool to enable the splice to be formed easily and quickly.
To the accomplishment of the foregoing and related ends the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but a few of the various ways in which the principles of the invention may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a completed or assembled splice in accordance with the invention;
FIG. 2 is a similar view with the locking collars and one jaw of the assembled splice removed;
FIG. 3 is a perspective view of one of the jaws;
FIG. 4 is a bottom elevation of the jaw of FIG. 3;
FIG. 5 is an axial end elevation of the jaw as seen from the right hand end of FIG. 4;
FIG. 6 is a plan view elevation of the jaw as seen from the left hand side of FIG. 5;
FIG. 7 is an enlarged axial section of a preferred jaw tooth profile;
FIG. 8 is an axial end elevation with the bar in section of the jaw assembly contracted and gripping the bar ends;
FIG. 9 is a perspective of a plastic spacer for assembling the jaw elements with one jaw removed for clarity of illustration;
FIG. 10 is a similar perspective view of the splice assembly with the jaws open and locking collars assembled but not in locking positions; and
FIG. 11 is a perspective view of an installation tool for closing the jaw assembly from each axial end while placing locking collars on both axial ends.
DETAILED DESCRIPTION
Referring initially to FIGS. 1 and 2, there is illustrated a reinforcing bar connection in accordance with the present invention shown generally at 20 joining end-to-end axially aligned deformed reinforcing bars 21 and 22 . The reinforcing bars are shown broken away so that only the ends gripped by the splice or connection are illustrated. It will be appreciated that the bars may extend to a substantial length and may either be vertical, horizontal, or even diagonal in the steel reinforced concrete construction taking place. The connection and bars are designed to be embedded in poured concrete. The connection comprises a jaw assembly shown generally at 24 , which includes three circumferentially interfitting three jaw elements shown at 25 , 26 and 27 . It will be appreciated that alternatively two jaw elements or more than three jaw elements may form the assembly 24 .
As seen more clearly in FIG. 2, the exterior of the jaw elements forms oppositely tapering shallow angle surfaces seen at 29 and 30 , on which are axially driven matching taper lock collars 32 and 33 , respectively. When the lock collars 32 and 33 are driven toward each other, the jaw assembly 24 contacts driving the interior teeth shown at 35 on each jaw element into the deformed, or projecting portions, of the bar such as the longitudinal projecting ribs 36 and the circumferential ribs 37 . The projecting rib formation on the exterior of the bars may vary widely, but most deformed bars have either a pattern like that shown or one similar to such pattern. The teeth 35 are designed to bite into such radial projections on the bar, but not into the core 38 , which forms the nominal diameter of the bar. It should be again noted that in FIG. 2, the jaw element 26 has been removed as well as the lock collars 32 and 33 to illustrate the interior teeth 35 .
Referring now to FIGS. 3 through 7, there is illustrated a single jaw 26 . Each of the three jaws forming the jaw assembly 24 are identical in form. Each jaw is a one-piece construction and is preferably formed of forged steel heat treated and stress relieved.
As seen more clearly in FIG. 5, since three jaw elements form the jaw assembly, each jaw element extends on an arc of approximately 120°. As seen more clearly in FIGS. 3 and 5, the 120° extends from one axial, or longitudinal, edge 40 to the other seen at 41 Such edges or seams between the jaw elements are axially parallel and uninterrupted except for the circumferential recesses 42 in the longitudinal edge 40 and the interfitting projection 43 on the longitudinal edge 41 . Each projection 43 is designed to fit into the notch 42 of the circumferentially adjacent jaw element. The interfitting projections and notches ensure that the jaw elements do not become axially misaligned as the connection is formed. The interfitting circumferential projections and notches also ensure that the jaw assembly remains an assembly as the splice is formed. The interfit of the circumferential projections with the notches of adjacent jaw elements is seen more clearly in FIG. 1 . The interfitting projections and notches may extend approximately 20° into or beyond the longitudinal seams.
As seen more clearly in FIGS. 4 and 6, each jaw element tapers from its thinnest wall section at the opposite ends 45 and 46 to its thickest wall section shown in the middle at 47 . The taper surfaces formed by the exterior of the jaw elements are low angle, self-locking tapers of but a few degrees and, of course, the tapers match the interior taper of the taper collars 32 and 33 which are driven axially on the end of the splice. The taper is preferably a low angle taper on the order from about one to about five degrees.
The taper exterior of the opposite ends of the jaw elements as well as the jaw assembly not only enables the matching lock collars to be driven on the splice, contracting the jaw elements with great force but locking them in contracted position. The configuration of the connection also enhances the dynamic and fatigue characteristics of the splice. This not only enhances the fatigue characteristics of the splice, but also enables the splice to qualify as a Type 2 coupler which may be used anywhere in a structure in any of the four earthquake zones of the U.S.
Referring now to FIG. 7, it will be seen that the interior of each jaw element is provided with a series of relatively sharp teeth 35 , which in the illustrated embodiment are shown as annular. However, it will be appreciated that a thread form of tooth may be employed. Each tooth 35 includes a sloping flank 50 on the side of the tooth toward the end of the jaw element. However, toward the middle of the jaw element, the tooth has an almost right angular flank 51 which meets flank 50 at the relatively sharp crown 52 . The flank 50 may be approximately 60° with respect to the axis of the jaw element while the flank 51 that is almost 90°. It will be appreciated that the teeth 35 may alternatively have other suitable configurations.
As seen in comparing the left and right hand side of FIG. 6, the teeth on the opposite end are again arranged with the angled flank on the exterior while the sharper almost perpendicular flank faces the mid-point 47 of the jaw element.
As indicated, the inward projection of the teeth is designed to bite into the projecting deformations on the bar, but not into the core 38 . As the teeth 35 press into the deformation, they provide additional cold working of the bar, resulting in better performance of the connection. By not pressing the teeth 35 into the core 38 of the bar, fatigue cracks and/or stress concentrations may thereby be avoided.
The three jaw elements are shown in FIG. 8 closed with the teeth 35 of the jaw elements biting into the bar deformation projections 36 and 37 , but not into the bar core 38 . When closed, the three longitudinal seams between the jaw elements seen at 54 , 55 and 56 will be substantially closed preventing further contraction of the jaw assembly keeping the teeth from biting into the core. The total contraction of the splice is controlled both by the circumferential dimensions and the axial extent to which the lock collars are driven on each end of the splice.
It will be appreciated that a transition splice may be formed with the present invention simply by reducing the interior diameter of one end of the splice so that the teeth on that end will bite into the projecting deformations on a smaller bar. The exterior configuration of the jaw elements may also change or remain the same with different size or identical locking collars driven on each end.
It will be appreciated that alternatively other means may be utilized for contracting internally-toothed jaw elements to clamp ends of reinforcing bars, for example by use of a radially-contracting collar or band.
Referring now to FIGS. 9 and 10, there is illustrated a splice assembly 59 where the jaw elements are held open and spaced from each other by a plastic spacer shown generally at 60 . The plastic spacer comprises three generally axial or longitudinal elements seen at 61 , 62 and 63 , each of which includes a center lateral projection 64 and an opposite notch 65 . The projection 64 snugly fits into the notch 42 of the jaw element while the notch 65 receives the projection 43 of the adjacent jaw element in a snug fit.
The three axially extending or longitudinal elements are held in place with respect to each other by the center three-legged triangular connection shown generally at 68 , which also acts as a bar end stop. In this manner, the three jaw elements are held assembled and circumferentially spaced. Each locking collar may be positioned on the end of the assembled jaw elements as seen at 32 and 33 and held in place by a shrink wrap, for example, as seen at 70 and 71 , in FIG. 10, respectively. In this manner, the jaw elements are held circumferentially spaced as seen by the gaps 72 . The assembly seen in FIG. 10 may readily be slipped over the end of a reinforcing bar and the end of the bar will be positioned in the middle of the splice by contact of the bar end with the triangular leg center connection 68 . When the opposite bar end is inserted into the open and assembled splice, the jaw assembly may then be closed by driving the two lock collars 32 and 33 axially toward each other. The force of driving on the lock collars will disintegrate not only the shrink wrap 70 and 71 , but also the support 60 which is made preferably of a frangible or friable plastic material. This then permits the jaw assembly to close to the extent required to bite into the radial bar projections to form a proper high fatigue strength coupling joining the two bar ends.
Referring now to FIG. 11, there is illustrated a tool shown generally at 78 for completing the splice or connection of the present invention. Although the tool is shown connecting the bars 21 and 22 vertically oriented, it will be appreciated that the bars and splice may be horizontally or even diagonally oriented. The tool is preferably made of high strength aluminum members to reduce its weight and includes generally parallel levers 79 and 80 connected by center link 81 pivoted to the approximate mid-point of such levers as indicated at 82 and 83 . Connecting the outer or right hand end of the levers 79 and 80 is an adjustable link shown generally at 85 in the form of a piston-cylinder assembly actuator 86 . The adjustable link may also be a turnbuckle or air motor, for example. The rod 87 of the assembly is provided with a clevis 88 pivoted at 89 to the outer end of lever 79 . The cylinder of the assembly 91 is provided with a mounting bracket or clevis 92 pivoted at 93 to the outer end of lever 80 .
The opposite end of the lever 79 is provided with a C-shape termination pivoted at 96 to a C-shape tubular member 97 having an open side 98 . A wedge driving collar shown generally at 100 is mounted on the lower end of the open tube 97 . The collar is formed of hinged semi-circular halves 101 and 102 . When closed and locked, the wedge collar has an interior taper matching that of the taper collars 32 or 33 .
The lower arm 80 similarly is provided with a C-termination 105 pivoted at 106 to open tube 107 supporting wedge collar 108 formed of pivotally connected semicircular halves 109 and 110 .
In order to make a splice, the coupler or splice assembly 59 seen more clearly in FIG. 10 is aligned with a first bar 21 , for example. The coupler assembly is then slid onto the bar end. A second bar 22 is then positioned in line with a coupler and the second bar is slid into position such that the coupler is centered between both bars. The bar ends will contact the triangular spider connection in the center of the bar splice assembly to ensure that the bar ends are properly seated with respect to the coupler assembly. The tool with the wedge collars 100 or 108 open is then positioned over the bars. The wedge collars are closed and the actuator, or piston cylinder assembly 86 , is extended to drive the wedge collars toward each other, driving the taper lock collars 32 and 33 on the jaw assembly to the position seen in FIG. 1, forming the splice 20 . The wedge collars 100 and 108 are then opened and the tool removed. The taper lock collars 32 and 33 remain in place. When the taper lock collars are driven on the ends of the splice or connection, the jaw elements contract and the teeth on the interior bite into the projecting deformations on the bar ends, but do not bite into the core diameter of the bar.
It will be seen that the present invention provides a high strength coupler or splice which will qualify as a Type 2 coupler and yet which is easy to assemble and join in the field and which does not require bar end preparation or torquing in the assembly process.
Although the invention has been shown and described with respect to certain preferred embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification. It will be appreciated that suitable features in one of the embodiments may be incorporated in another of the embodiments, if desired. The present invention includes all such equivalent alterations and modifications, and is limited only be the scope of the claims. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a capsule filling apparatus, and more particularly to an apparatus for filling rigid capsules made of gelatin with tablets of the same cylindroidal shape as the capsule, wherein the capsules were held in an upright posture with the openings upward.
2. Description of the Prior Art
It is common practice to fill a rigid capsule made of gelatin with a fluid substance such as granular, powder or liquid medicine. Sometimes, such capsules are also filled with solid tablets, and in recent years, with tablets having the same cylindroidal shape as the capsule itself. Being covered with the capsule in this way, the tablet can be protected from damage or deformation. This is also advantageous in eliminating the necessity of putting identification marks or coloring directly upon the tablets but only putting it on the capsules themselves.
Japanese Laid-Open Patent Publication No. 52-39494 discloses an apparatus for filling a capsule with a disk-shaped tablet. In this capsule filling apparatus, a disk-shaped tablet fed into a chute is passed into a hole extending through a slider. The slider is then moved in the horizontal direction so as to send the tablet held inside the hole through a hole in a shutter into a capsule. The filling of the capsule is detected by the displacement of a detecting rod to be inserted in the capsule.
When a capsule is filled with a tablet having the same shape as the capsule, the tablet must be inserted upright into the capsule which is also held upright. It is difficult, however, to form a sequence of upright cylindroidal tablets in a vertical line. Tablets may not be fed continuously into capsules through the hole in the slider, thereby resulting in the failure of filling the capsules with them. The problem of empty capsules sometimes occurs. To solve this problem, care must be taken to maintain the supply of tablets into capsules.
The above-mentioned capsule filling apparatus employs a detecting rod which is inserted into a capsule after the capsule is filled with a tablet. The filling of the tablet is detected by the displacement of the detecting rod. In this arrangement, however, the detecting rod touches the tablet and may damage it. Moreover, ingredients of the tablet may stick to the tip of the detecting rod, which must be cleaned before a different kind of tablet is charged in the capsule.
Furthermore, when the capsule is filled with a capsule-shaped tablet, the upright tablet may not completely fit into the hole of the slider, and is likely to be suspended between the chute and the slider. When the slider is moved under this condition, the tablet may be cut off by a shearing force applied between the hole of the slider and the chute.
SUMMARY OF THE INVENTION
The capsule filling apparatus of this invention, which overcomes the above-discussed and numerous other disadvantages and deficiencies of the prior art, comprises a first tablet feed part for feeding tablets into a hopper one by one in an upright posture, a slider disposed below the first tablet feed part, the slider having holes each extending therethrough so as to allow the tablets fed from the first tablet feed part to pass therethrough, and a shutter disposed below the slider, the shutter having guiding holes each extending therethrough and facing at the bottom end each opening of the capsule body so as to allow the tablets fed from the slider to pass therethrough, and means for detecting whether the tablets are properly placed in the holes of the slider, the slider horizontally moving to enable the bottom end of each hole thereof to be positioned one time to face each guiding hole of the shutter and the other to face each means for detecting the tablets in the holes.
In a preferred embodiment, the means for detecting the tablets of the shutter comprises air suction tubes each provided with an air suction opening at the top thereof, the air suction opening having a smaller diameter than that of the tablet, pressure sensors for detecting the internal pressure of the air suction tubes, and an air suction pump for reducing the internal pressure of the air suction tubes.
In a preferred embodiment, the shutter is made movable in the same direction as the slider.
In a preferred embodiment, the first tablet feed part is attached to an eccentric portion of a rotation axis.
In a preferred embodiment, the hopper disposed in the first tablet feed part is oscillated in the horizontal direction.
In a preferred embodiment, the first tablet feed part includes a feed block having holes shaped like a truncated cone whose top opening is larger than the bottom opening, the diameter of the top opening being smaller than the length of the tablet, whereas that of the bottom opening larger than the width thereof.
Thus, the capsule filling apparatus described herein makes possible the objectives of (1) filling the capsule with a tablet of the same shape as the capsule smoothly and continuously by oscillating the hopper so that the tablets can be fed from the hopper without being caught, and (2) ensuring to detect whether the capsule body is completely filled with the tablet without damaging the tablet.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings as follows:
FIG. 1 is a sectional view of a main part of one embodiment of the capsule filling apparatus according to the present invention;
FIG. 2 and FIG. 3 are partial sectional views illustrating the operation of the embodiment of FIG. 1, respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENT
One embodiment according to the present invention is described as follows.
The capsule filling apparatus of this invention is used to fill a rigid capsule with a tablet of the same cylindroidal shape as the capsule. The capsule is formed of a cylindroidal capsule body and a capsule cap each with an opening at one end, and at the filling the capsule cap is separated from the capsule body. Before being filled with tablets by the capsule filling apparatus according to the present invention, a group of capsules are set in an array, by means of, for example, the capsule direction regulating mechanism disclosed in Japanese Laid-Open Patent Publication No. 61-211213, in such a manner that each capsule is placed upright with the capsule cap upward and the capsule body and capsule cap loosely connected so as to be easily separated from each other afterwards and still keeping the orderly array of the capsules. Then, the array of capsule bodies with a fixed space between them are conveyed in the horizontal direction to a fixed place by means of an annular capsule body conveying mechanism 60 disposed horizontally as shown in FIG. 1. The capsule bodies in the array are regularly arranged like a checkerboard.
The capsule filling apparatus according to the present invention is mounted on the side of the fixed place of the capsule body conveying mechanism 60 as shown in FIG. 1.
The capsule filling apparatus comprises a cylindrical support 12 vertically held onto a hollow base 11. At the upper portion of the support 12 is located a first feed part 20 which is supported by the support 12 and includes a hopper 24 for receiving tablets and a guide block 26 for guiding the tablets so that they are fed in an upright posture from the hopper 24. The guide block 26 is disposed to correspond to the fixed place of the capsule body conveying mechanism 60. Between the guide block 26 and the capsule body conveying mechanism 60 is located a second tablet feed part 40.
Through the cylindrical support 12 extends a rotation axis 13, of which top and bottom portions are rotatably secured to the top and bottom portions of the support 12 through bearings 14 and 44, respectively. The bottom portion of the rotation axis 13 extends beyond the bottom end of the support 12 to reach the inside of the base 11. A pulley 15 is connected around the extended bottom portion of the rotation axis 13. A motor 16 is mounted on the base 11 at the opposite side to the capsule body conveying mechanism 60 with respect to the support 12, so that its output axis is positioned in the vertical direction and extends downward into the base 11. A pulley 17 is connected around the extended bottom portion of the output axis. Between this pulley and the pulley 15 connected around the rotation axis 13 is wound a belt 18, so that the rotation generated by the motor 16 is transmitted to the rotation axis 13 through the belt 18.
The top portion of the rotation axis 13 extends beyond the top end of the support 12, and the extended portion of the rotation axis 13 forms an eccentric portion 13a. To the eccentric portion 13a is attached an oscillating portion 21 of the first tablet feed part 20.
The oscillating portion 21 includes a coupling block 21a disposed around the eccentric portion 13a and a feed block 21b horizontally supported by the coupling block 21a. The eccentric portion 13a is slightly made eccentric against the other portion of the rotation axis 13 secured within the support 12. The coupling block 21a is rotatably fitted around the eccentric portion 13a through a pair of bearings 23, causing the entire oscillating portion 21 to slightly oscillate in the horizontal direction when the rotation axis 13 rotates.
The hopper 24 is mounted on the feed block 21b supported by the coupling block 21a. Into the hopper 24 are supplied tablets 80 of the same cylindroidal shape as the capsule. The tablets 80 move within the hopper toward the area above the feed block 21b.
The feed block 21b is horizontally placed above the capsule body conveying mechanism 60. A plurality of holes 21c extend through the feed block 21b in the same arrangement as the array of capsule bodies 71 on the mechanism 60 so that each hole 21c corresponds to each capsule body 71. Each hole 21c, with the vertical axis, is shaped like a truncated cone with its top opening larger than its bottom opening. The top opening of the hole 21c has a diameter slightly smaller than the length of the capsule-shaped tablet 80, while the bottom opening thereof has a diameter slightly larger than the width of the tablet 80. When the oscillating portion 21 is oscillated through the rotation of the rotation axis 13, each tablet 80 in the hopper 24 starts to enter each hole 21c with a longitudinal end of the tablet ahead.
A number of chutes 26a extend through the guide block 26 attached to the upper portion of the support 12. The top end of each chute 26a roughly faces the bottom end of each hole 21c of the feed block 21b. The diameter of each chute 26a is slightly larger than the width of the tablet 80, so that the tablets 80 which have passed through the holes 21c are introduced one after another to the chutes 26a in a roughly upright posture. Each chute 26a is arranged to accommodate several upright tablets 80 (five in this embodiment) in a line.
The second tablet feed part 40 located below the guide block 26 includes a slider 41 horizontally disposed below the guide block 26 and a shutter 42 horizontally disposed below the slider 41. The slider 41 is supported by a pair of support axes 43 which horizontally extend through the support 12. The ends of the support axes 43 opposite the ones attached to the slider 41, which are located above the motor 16, are connected to each other by means of a coupling rod 44. Between the center portion of the coupling rod 44 and the support 12 is horizontally disposed an air cylinder 45, which operates to push the coupling rod 44 to move toward or away from the support 12, causing the synchronous parallel movement of the pair of support axes 43 in the horizontal direction.
To the air cylinder 45 is attached a load sensor 49 for detecting a high load applied to the air cylinder 45.
The slider 41 supported by the support axes 43 is provided with a number of holes 41a vertically extending therethrough. These holes 41a are formed in the same arrangement as the chutes 26a of the guide block 26 and accept the tablets 80. The length of each hole 41a is made slightly smaller than the length of the tablet 80. When the slider 41 moves toward the support 12 by the operation of the air cylinder 45, each hole 41a faces the bottom end of each chute 26a in an aligned condition. Meanwhile, when the slider 41 moves away from the support 12, the upper surface between the holes 41a of the slider 41 faces the bottom end of each chute 26a.
The shutter 42 disposed below the slider 41 is supported by a pair of support axes 46 horizontally extending through the support 12 in the same manner a the slider 41. The ends of the support axes 46 located above the motor 16 are connected to each other by means of a coupling rod 47. Between the center portion of the coupling rod 47 and the support 12 is horizontally disposed an air cylinder 48, which operates to push the coupling rod 47 to move toward or away from the support 12, causing the synchronous parallel movement of the pair of support axes 46 in the horizontal direction.
The shutter 42 is provided with a number of guide holes 42a vertically extending therethrough. These guide holes 42a are formed in the same arrangement as the holes 41a of the slider 41 and the chutes 26a of the guide block 26. Normally, each guide hole 42a is made to face each hole 41a of the slider 41 when the slider 41 above the shutter 42 moves away from the support 12.
The shutter 42 is also provided with air suction openings 42c for air suction tubes 42b, each facing the axis portion of each hole 41a of the slider 41 when the slider 41 is moved toward the support 12. Each air suction opening 42c is made sufficiently smaller than the chute 26a in diameter to prevent the capsule-shaped tablet from entering the air suction opening. The air suction tubes 42b extend through the shutter 42 so as not to communicate with any of the guide holes 42a, and are connected to an air suction pump 51 at the ends. At a point along each air suction tube 42b is disposed a pressure sensor 52 which detects air pressure inside the air suction tube 42b.
The operation of the thus arranged capsule filling apparatus is described as follows.
When the capsule-shaped tablet 80 has been put in the hopper 24 of the first tablet feed part 20, the array of capsule bodies on the capsule body conveying mechanism 60 is brought below the second tablet feed part 40. At this time, both the slider 41 and the shutter 42 of the second tablet feed part 40 have been moved away from the support 12. (Refer to FIG. 3.) Under the above conditions, each capsule body 71 held on the capsule body conveying mechanism 60 with its opening upward faces each guide hole 42a of the shutter 42. The top end of each hole 41a of the slider 41 does not face the bottom end of each chute 26a of the guide block 26, which is therefore closed by the upper surface of the slider 41, while the lower end of each hole 41a of the slider 41 faces each guide hole 42a of the shutter 42.
First, under the above described conditions, the motor 16 is driven to initiate the rotation of the rotation axis 13 which extends through the support 12. Then, the eccentric portion 13a formed on the top portion of the rotation axis 13 is eccentrically rotated, causing the oscillating portion 21 attached to the eccentric portion 13a to oscillate in the horizontal direction. This horizontal oscillation is transmitted to the hopper 24 mounted on the oscillating portion 21, giving vibration to the tablets 80 inside the hopper 24. The vibrated capsule-shaped tablets 80 in the hopper 24 then start to enter each hole 21c of the feed block 21b one by one with a longitudinal end of the tablet ahead. The tablets 80 thus made to stand in an upright posture through each hole 21c then fall one by one into each chute 26a of the guide block 26, forming a continuous line of upright tablets in each chute 26a as the bottom end thereof is closed by the upper surface of the slider 41 at this time.
Second, the air cylinder 45 is driven so as to cause the slider 41 of the second tablet feed part 40 to horizontally move toward the support 12. Hence, as shown in FIG. 2, each hole 41a of the slider 41 faces each chute 26a of the guide block 26 at the top end and faces each air suction opening 42c of the shutter 42 at the bottom end. Under this positioning, the tablet 80 placed on the bottom of each chute 26a of the guide block 41 falls into the hole 41a of the slider 41 by its own weight. As the bottom end of each hole 41a of the slider 41 faces each air suction opening 42c of the shutter 42, the tablet 80 is not passed through but held within the hole 41a. At this time, the bottom end of the tablet 80 closes the air suction opening 42c.
Third, the air suction pump 51 connected to the air suction tubes 42b is used to reduce the pressure inside the air suction tubes 42b. When the air suction opening 42c is closed by the bottom end of the tablet 80, air will not enter from the air suction opening 42c and the internal pressure of the air suction tube 42b is reduced. Therefore, when all of the holes 41a of the slider 41 are filled with tablets 80 closing all of the air suction openings 42c, the internal pressure of the air suction tubes 42b decreases to a prescribed degree. On the other hand, when any of the holes 41a is not filled with the tablet 80, the air suction opening 42c facing the hole 41a is not closed by the tablet 80, allowing the air flow through the air suction tube 42b and thus failing to decrease the internal pressure thereof to the prescribed degree. The pressure sensors 52 disposed in the air suction tubes 42b detect the internal pressure of the air suction tubes 42b to determine whether all of the holes 41a of the slider 41 are filled with the tablets 80.
Incidentally, when any hole 41a of the slider 41 is not filled with the tablet 80, the tablet 80 placed in the chute 26a of the guide block 26 may be sucked into the hole 41a by the air suction at the air suction opening 42c.
Fourth, the air cylinder 45 is used to allow the slider 41 to horizontally move away from the support 12. This causes the bottom end of each hole 41a of the slider 41 to face each guide hole 42a of the shutter 42. As shown in FIG. 3, the capsule-shaped tablet 80 held in each hole 41a of the slider 41 then falls through each guide hole 42a of the shutter 42 into each capsule body 71 held on the capsule body conveying mechanism 60. At this moment, the upper surface of the slider 41 closes the bottom end of each chute 26a of the guide block 26, not allowing the bottom tablet 80 in each chute 26a to fall into each hole 41a.
In the case where the tablet 80 held in the hole 41a of the slider 41 has not completely fallen into the guide hole 42a of the shutter 42 but is suspended between the two holes, the air cylinder 45 is heavily loaded when the slider 41 starts again to move toward the support 12. The load sensor 49 detects this loading and operates to initiate the air cylinder 48, which moves the shutter 42 toward the support 12, thus allowing the tablet 80 suspended between the two holes to fall into the guide hole 42a so as to be discharged. At this time, the capsule body conveying mechanism 60 has been moved away from the fixed place below the shutter 42.
Thus, when each capsule body 71 in the array on the fixed place of the capsule body conveying mechanism 60 completes the filling, the capsule body conveying mechanism 60 is driven to set a new array of empty capsule bodies on the fixed position below the second tablet feed part 40, and the same steps as described above are repeated.
It is understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the scope and spirit of this invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but rather that the claims be construed as encompassing all the features of patentable novelty that reside in the present invention, including all features that would be treated as equivalents thereof by those skilled in the art to which this invention pertains. | 4y
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BACKGROUND OF THE INVENTION
The invention relates to electrical cabinets.
Electrical cabinets are used for receiving electronic and electrical components particularly but not exclusively for the operation of local data networks. The components such as sub-racks with electronic and electrical components, fans and other accessories are mounted within the cabinet on internal frames and the cabinets generally have side panels, a door and end panels and are mounted on a frame which preferably comprises upper and lower end members and vertically extending side members preferably provided one towards the front and the other towards the rear at each lateral side of the cabinet.
SUMMARY OF THE INVENTION
According to one aspect of the invention, panel mounts, comprising members to extend vertically within the cabinet and having attachment means whereby panels can be mounted thereupon, are mounted to the side members of the cabinet by integral members which extend substantially parallel to the outer face of the panel mount at a spacing from the outer face and in a direction perpendicular to the longitudinal extent of the panel mount, such integral members each being engaged in a respective aperture in the side members or braces extending between the side members at one lateral side of the cabinet, followed by movement forwardly or rearwardly to secure the panel mount to the side members, retaining means such as a pin or stud then being inserted in aligned bores in the panel mounts and side members or braces to prevent return movement in said forward or rearward directions.
Such method of securement can have the advantage over previously proposed methods which involved vertical movement of the panel mounts to secure them, that panel mounts of the full height of the side members can be secured to the side members where previously, due to the vertical movement experienced during the engagement, it was necessary for the panel mount to be significantly shorter than the side member. The panel mounts, which generally define a 483 mm (19 inch) wide mounting, can thus be secured at various locations in the depth of the cabinet and can extend for the full height of the side members.
Preferably the apertures in the side members or braces are spaced at 25 mm horizontal spacing to set the locations at which the panel mounts can be secured at 25 mm spacings.
Advantageously the braces have horizontally elongate slots therein in addition to the apertures whereby the braces can be secured by fastenings means, such as bolts, extending through the slots whereby the braces are horizontally movable with respect to the side members to permit the panel mounts to be secured at any desired location in the depth of the cabinet.
According to another aspect of the invention in an electrical cabinet chassis supports, for example for supporting shelves, are provided in the form of cantilevers by providing the chassis supports with vertically spaced securing hooks which together are capable of preventing pivoting movement of a mounted article such as a shelf.
The vertically spaced hooks may project longitudinally of a wall of the chassis support and parallel thereto to be engaged in respective apertures in a member from which they are to be supported.
According to a further aspect of the invention, means to secure in abutment two rectangular section tubular metal members with their longitudinally axes mutually at right angles comprises punching or drilling at least two first holes in one wall of each of the metal members, acting through the first holes so formed to burst a respective second hole to each first hole in the opposite wall of the metal members to form an outwardly extending collar, screw threading the second holes in one of the members, engaging the collars of the other of the members in the first holes of said one of the members and engaging a bolt through the aligned first and second holes of said one and said other members to engage the screw thread in the collar of said one of the members to clamp the members together.
According to a still further aspect of the invention, in an electrical cabinet a method of hanging a vertical side panel comprising engaging a top flange of the side panel, which top flange has a horizontal portion and a vertical return, over an upper suspension member of a frame of the cabinet and engaging a horizontal lower flange of the side panel with an upturned hook portion at the lower end of the frame of the cabinet so that the upturned hook projects upwardly through an aperture in the horizontal lower flange.
Preferably the aperture in the horizontal lower flange is aligned with a cutout in a free edge of the flange and engagement is effected by engaging the hook in the cutout and then slightly raising the side panel while pushing it inwardly towards the cabinet before lowering the side panel downwardly onto the hook.
The upper suspension member of the frame may be provided at the upper end of vertical side members of the frame or may be provided on extension pieces which are supported by the vertical side members and project laterally outwardly to extend the width of the cabinet beyond the side members. By using such extension pieces extra wiring accommodating spaces can be provided at one or both of the sides of a cabinet.
The extension pieces can have hooks to engage over the upper edge of the side members, preferably in a recess so that such upper edges are below the upper extremity of the side members, and be bolted to the side members to retain them in position. Preferably each extension piece can be used as either an upper or a lower extension piece.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is diagrammatically illustrated by way of example in the accompanying drawings, in which:—
FIG. 1 is a perspective view of a panel mount with attachment means and a side member on which it can be mounted according to the invention;
FIG. 1 a is a sectional end view of the panel mount of FIG. 1 ;
FIG. 2 is an elevation of a brace to which the panel mount of FIG. 1 can be secured;
FIG. 3 is a perspective view of an inner face of a chassis support with cantilever engagement hooks;
FIG. 4 is a view of the chassis support of FIG. 3 from the other side;
FIG. 5 is an exploded view showing components of an electrical cabinet;
FIG. 6 is a view of the portion of FIG. 5 indicated by the arrow VI but with a panel hung thereon;
FIG. 7 is a sectional view through two of the components shown in FIG. 6 ;
FIG. 8 is a schematic view indicating hanging of a vertical side panel of an electrical cabinet by a method according to the invention;
FIG. 9 is a sectional view taken on line IX—IX of FIG. 8 ;
FIG. 10 is a perspective view from above and an inner face of an extension member of an electrical cabinet according to the invention in a position to form an upper extension member;
FIG. 11 is a view from the other side of the extension member of FIG. 10 also orientated so as to form an upper member; and
FIG. 12 is a view of the extension member shown in FIGS. 10 and 11 but in an orientation to form a lower extension member.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings and firstly to FIGS. 1 and 2 , a panel mount 1 is a generally angular section strip of metal and in one face has a three sided cutout 2 with the portion of the wall cut out, bent outwardly and bent back to form a tongue 3 which extends parallel to the wall in which the cutout 2 is formed. The tongue 3 can be inserted in any one of horizontally spaced apertures in a vertical side member 5 forming part of the frame of an electrical cabinet or can be inserted in any one of horizontally spaced apertures 6 in a brace 7 which can be secured to the side members of the frame of an electrical cabinet on one side of the cabinet to extend between a front side member and a rear side member. The apertures 4 or 6 are spaced at a pitch of 25 mm and thus the panel mount 1 can be supported on the side member 5 or the brace 7 by inserting the tongue 3 in an aperture 4 or 6 and then moving the panel mount 1 to cause the tongue 3 to move behind the web of the side member 5 or the brace 7 in which the aperture 4 or 6 is formed. The panel mount 1 does thus not need to be moved vertically to secure it and can be of the same length as the side members so as to extend completely between upper and lower frame members of the cabinet. A through aperture 8 may be provided in the panel mount 1 through which a pin or clip (not shown) can be inserted to engage in an aperture 9 provided alongside the aperture 4 or 6 in which the tongue 3 is engaged thereby to prevent return movement which would free the tongue from the aperture 4 or 6 . Elongate slots 10 in the brace 7 can be used to secure the brace 7 by bolts to the side members, the length of the slots 10 allowing longitudinal shifting of the brace 7 with respect to the side members to allow stepless positioning of the panel mounts with respect to the side members 5 .
Referring to FIGS. 3 and 4 , a chassis support 11 is shown which comprises upper and lower flanges 12 and 13 above and below a vertical web 14 . In the web 14 two cutouts 15 are formed by cutting around three sides and the member formed by each cutout is pressed out of the plane of the web 14 by a bend 16 and a further bend 17 and the tongue so formed which extends parallel to the web 14 but spaced therefrom is cut away to form upper and lower hooks 18 , 19 . By providing the two spaced hooks the chassis support 11 can be engaged in two vertically spaced apertures and then moved downwardly so that the chassis support 11 is cantilevered from a pair of the hooks 18 , 19 and can resist tilting forces applied thereto. Although the chassis support 11 is shown as having two cutouts 15 and two pairs of hooks 18 , 19 it is only envisaged that one or other of the pairs of hooks would be used at any one time but by providing two cutouts the chassis support 11 can act as a lefthanded chassis support or a righthanded chassis support. The chassis supports 11 are particularly suitable for supporting shelves in electrical cabinets.
Referring to FIG. 5 , an electrical cabinet 20 , shown in exploded form, comprises an upper frame 21 and a lower frame 22 each formed by back-to-back U-shaped members 23 of tubular metal, four side members 24 extending between the upper frame 21 and the lower frame 22 , an upper member 25 with cutouts 25 a in three of the walls thereof, removable side panels 26 only one of which is shown and a removable door 27 which closes the front of the cabinet.
As can be seen in FIG. 6 , the side panel 26 has an upper horizontal flange 28 with a return vertical flange 29 , the panel 26 enveloping the two side members 24 on that side of the frame of the cupboard.
FIG. 7 shows the means whereby each of the U-shaped members 23 which extend horizontally can be mounted to the respective side members 24 which extend vertically. Two first holes 30 are punched or drilled in one wall 31 of the side member 24 and two first holes 32 are punched or drilled in one wall 33 of the U-shaped member 23 . Operating through the first holes 30 , 32 , second holes 34 are then burst through the second wall 35 of the side members 24 and second holes 36 are burst through the second wall 37 of the U-shaped member 23 . Bursting the holes in this way forms collars 38 at the outsides of the holes 34 and collars 39 at the outside of the holes 36 . The holes 36 are then screw threaded. When the members 23 , 24 are pressed together the collars 38 on the side members 24 are a push fit into the first holes 32 in the U-shaped member 23 so that when bolts (not shown) are inserted along the aligned axis 40 of each of the holes 30 , 34 , 32 , 36 to pull the members 23 , 24 tightly into engagement with one another, the members 23 , 24 are locked accurately at right angles one to the other without any play such that even a tall framework of U-shaped members 23 and side members 24 , for example two meters tall, can stand rigidly without a tendency for the upper frame to move sideways or from to rear due to the connections being less than entirely rigid. The collars 38 can however have a tapering formation such that great precision is not required in the formation of the holes and collars.
Referring to FIGS. 8 to 12 , the upper end of each side member 24 is provided with a formation similar to that shown in FIG. 10 at the righthand side thereof, that is to say it has a groove 41 in the upper face 42 stepped back from a front upper corner 43 . Actually the formation shown in FIG. 10 is an extension piece to be hung on the upper or lower end of one of the side members 24 but the formation of the top end and bottom end of the side members 24 is the same as shown in FIG. 10 .
Referring to FIG. 8 , the side panel 26 shown has its horizontal upper flange 28 overlapping the upper surface 42 of the side member 24 and its vertical flange 29 engaged in the groove 41 of the upper end of the side member 24 . At the lower end the side panel 26 has a horizontal flange 44 which, as shown in FIG. 9 , has, in alignment with each of the side members 24 , apertures 45 and cutouts 46 . At each side of the side member 24 both at the upper end and at the lower end a hook 47 is provided. The hook 47 at the upper end has no function but that at the lower end engages in a respective one of the apertures 45 . With reference again to FIG. 8 the method of engagement is that the panel 26 is first hooked onto the upper end of the side member so that the vertical flange 29 engages in the groove 41 . The bottom end of the panel 26 is then pushed inwardly to engage the hooks 47 in the cutouts 46 , a flared mouth of the cutouts 46 assisting this alignment. The side panel 26 is then raised slightly and pushed inwardly so that the hook 47 at the lower end of the side member 24 can engage in the respective aperture 45 in the bottom flange 44 of the side panel 26 . The side panels 26 can thus quickly and easily be engaged with or disengaged from the framework of the cabinet. It will be seen that the hooks 47 taper down towards their free ends such that the weight of the panel engages the edges of the apertures 45 both with the outer and with the inner faces of the hook 47 so that vibration will not cause rattling of the panel.
Referring now also to FIGS. 11 and 12 , the extension pieces 48 have, in addition to the groove 41 , the top face 42 , the front edge 43 and the hooks 47 previously described, a bent out tongue 49 and aligned apertures 50 , 51 by means of which they can be hooked onto and bolted to the outer face of the upper and lower ends of the side members 24 . The extension pieces 48 are preferably 100 mm between the front edge 43 and the upper edge of the face in which the tongue 49 is provided whereby they can space the side panels 26 outwardly from the side members 24 by 100 mm to give an additional space for extra wiring or other purposes. A blanking plate can extend between the door of the cabinet and the extended position of the side panels 26 to fill 100 mm space at the front. If two adjacent cabinets are each provided with extension pieces 48 on their adjacent sides then the two cabinets can be accurately spaced apart by 200 mm to form a wiring space therebetween, a suitable blanking plate being provided to cover the space to the front. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates broadly to medico-surgical tube structures and methods of their manufacture. More particularly, it concerns methods for finishing the distal ends of medico-surgical tubes, especially catheters.
2. Description of the Prior Art
Catheter distal end tips should not have sharp corners, sharp points, ragged edges or any other injury causing features. Manufacturers have either hand finished or molded the tips to eliminate such problems. Molding in heated cavities has become the common method (see U.S. Pat. No. 3,725,522).
One problem associated with the molding method is the trapping of air in and around the molten plastic at the bottom of the heated mold. As the tube is forced down into the mold, air becomes compressed ahead of it much the same as a piston being forced into a cylinder. If there is no means for the air to escape, it prevents the plastic from taking the shape of the mold, or some air may become trapped within the plastic as a bubble or blister.
Two methods are commonly used to deal with the air trapping problem. One is to provide a bleed hole to let the air escape (see U.S. Pat. Nos. 3,725,522 and 4,292,270). A second is to provide enough clearance around the tube and the mold cavity so air can escape back up the cavity. However, by doing either of these, new problems can be created.
In the bleed hole method, while the hole allows the softened plastic to take the shape of the mold, some plastic may be extruded through the bleed hole. When the tube is then removed from the mold, it is left with a projection or other evidence where the bleed stringer has broken off. If the second method is used, it is possible that the molten plastic can be forced back up the clearance space. This can produce a flap or ridge which is undesireable.
OBJECTS
A principal object of this invention is the provision of new methods for the finishing of the ends of medico-surgical tubes. Further objects include the provision of:
1. New methods for creating smooth tips on the distal ends of catheters without the simultaneous production of sprue projections or flash.
2. A new technique for eliminating the trapped air problem in the finishing of the distal ends of catheters by forcing the distal end into a heated mold.
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 the 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 from this detailed description.
SUMMARY OF THE INVENTION
These objects are accomplished according to the present invention by a method of finishing the distal end of a plastic catheter having a major central lumen which comprises providing a cup-like mold contoured to the shape desired for the finished distal end including a raised central portion to project into the catheter's central lumen when it is inserted in the mold, heating the mold to a temperature above the plastic flow temperature of the catheter, forcing the distal end of the catheter into the mold, and simultaneously applying suction to the central lumen of the catheter.
In one preferred embodiment of the invention the suction is applied to the proximal end of the catheter lumen. In another embodiment, the suction is applied through a raised central portion of the mold.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention may be had by reference to the accompanying drawings in which:
FIG. 1 is a sectional view showing the finishing of the end of a catheter in a mold of the invention in accordance with one embodiment of the invention.
FIG. 2 is a sectional view showing the finishing of the end of a catheter in accordance with another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring in detail in the drawings and, in particular, in FIG. 1, the molding device 2 comprises a cup-like mold 4 contoured to the shape desired to be formed in the distal end 6 of the catheter 8. The contour of the mold 4 includes the tube tip shaping bottom 10, sidewall 12 and entrance lip 14.
The mold 4 further comprises a raised central portion 16 designed to project into the central lumen 18 of the catheter 8 when it is inserted into the mold 4. The portion 16 in the embodiment of FIG. 1 is in the form of a solid pin, but it may instead be in the form of a hollow tube closed at the top.
The clearances between the catheter walls 20 and 22 and the surfaces of the mold sidewalls 12 and the central portion 16, respectively, are designed close enough so that the catheter 8 can be inserted without interference, but not with clearance to the extent that molten plastic can flow back up the inside of wall 12 or the outside of central portion 16.
The molding device 2 includes suction tube 24 provided with a cap 26 to fit over the proximal end 28 of the catheter lumen 18. A typical cycle for finishing the catheter 8 in the molding device 2 is as follows: The catheter distal end 6 is inserted into the entering portion of the mold cavity. The suction tube 24 is connected to a vacuum source (not shown) and the finishing cycle is initiated by applying a suction to the tube 24 from the vacuum source, e.g., with a vacuum potential of 22" to 29" Hg. This produces a suction on the inside of the catheter 6. Such applied suction draws the catheter toward the bottom 10 of the mold 4. The cycle is programmed so that the mold bottom 10 will be heated when the suction is applied, or heating of the mold may be delayed a predetermined amount. Downward pressure on the catheter is applied by hand or this may be done by electrical, mechanical or fluid pressure devices (not shown). The combination of downward pressure on the catheter forcing it toward the bottom 10 of the mold 4 plus the application of the heat bringing the plastic to a flowing (molten) condition and evacuation of any air that may, in the absence of the suctioning, become entrapped between the catheter and the mold, permits the flowing plastic to fully fill the mold bottom 10 to form the desired shape on the catheter tip without sprue projections, flash or the like.
Suction need only be applied during the part of the finishing cycle when the catheter is advancing downward to the mold bottom 10 with the plastic of the catheter heated to flowable condition. During the period of cooling, heat and vacuum are removed, but the downward pressure on the catheter is advantageously continued through the cooling stage of the finishing cycle.
The molding device 2A of FIG. 2 is essentially like that of FIG. 1. except for the central portion 16A which is of tubular form that includes an integral outlet tube 30. In the finishing cycle using the device 2A, the tube 30 is connected via hose 32 to the vacuum source (not shown) and the proximal end 20 of catheter 8 is closed with a cap 32. Suction is applied via the tube 30 in the initial stage of the finishing cycle as contrasted to its application via tube 24 in the molding device 2. Otherwise the finishing operation parallels that described for device 2.
In the foregoing description, only one catheter tip configuration is illustrated, but it should be understood that a variety of different tip shapes may be made by the new finishing methods. | 4y
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FIELD OF THE DISCLOSURE
The present disclosure relates in general to storage tanks for liquids, and in particular to open-top modular storage tanks used in the petroleum industry and other industries that require large-scale and inexpensive liquid storage such as for fire-fighting water (field and municipal), potable water storage (remote and municipal), water for fish farming (fresh and sea), mining, etc. More particularly, the disclosure relates to systems and methods for constructing a circular storage tank with secondary containment means to contain liquid escaping the storage tank in the event of leakage.
BACKGROUND
It is increasingly common in the oil and gas industry to use hydraulic fracturing (colloquially known as “fraccing” or “fracking”) to aid in the recovery of hydrocarbon fluids such as crude oil and natural gas from subsurface formations. Hydraulic fracturing is a process involving the injection of a “fraccing fluid” (or “frac fluid”) under pressure into spaces such as cracks and fissures within a subsurface petroleum-bearing formation, such that the fluid pressure forces the cracks and fissures to become larger, and/or induces new fractures in the formation materials, resulting in more and/or larger flow paths through which hydrocarbon fluids can flow out of the formation and into a well drilled into the formation. Fraccing fluids typically carry particulate materials called “proppants” that are intended to stay inside the enlarged or newly-created subterranean fissures after the fraccing fluid has been drained out of the formation and hydraulic pressure has been relieved.
There are various different types and formulations of fraccing fluids, but regardless of the type of fraccing fluid being used, one thing common to all fraccing operations is the need for temporary storage of very large volumes of fraccing fluid at the well site, both to provide a reservoir of frac fluid for injection into subsurface formations, and to store frac fluid circulated out of the well after completion of fraccing operations. Storage tanks having volumes of 250,000 to 2,500,000 U.S. gallons or more are commonly required for this purpose.
For practical and environmental reasons, such tanks are typically of modular design so that their components can be shipped by truck to remote well sites, where they can be erected on site and eventually disassembled and shipped off site after they are no longer needed. Open-top liquid storage tanks most commonly are circular, as this is the most stable and efficient structural configuration for a liquid storage tank. Modular circular tanks typically comprise multiple horizontally-curved steel wall panels having a radius corresponding to the radius of the finished tank. The vertical side edges of each curved wall panel abut and are fastened to the vertical side edges of adjacent wall panels by suitable structural connection means, such that when all of the wall panels have been erected and interconnected, they form a circular tank having a particular height, diameter, and liquid storage capacity. A suitable liquid-tight liner is then installed inside the tank, covering a prepared ground surface inside the tank perimeter and extending up and typically over the tank wall. The tank is then ready to receive a fraccing fluid or other liquid that needs to be stored.
Environmental regulations require storage tanks for many different types of liquids to be provided with secondary containment means to protect against environmental contamination in the event of a tank leak. For example, petroleum storage tanks are commonly constructed within a containment reservoir formed by earthen berms lined with synthetic liners or engineered clay liners installed or constructed below the ground surface. Such secondary containment means may be practical for “tank farm” installations where the primary liquid storage tanks are essentially permanent. However, they are not a practical or acceptable option on well sites requiring tanks for temporary storage of large volumes of liquid (such as fraccing fluid) and where such temporary tanks must be demountable so as to cause little or no permanent environmental disturbance in the area where the temporary tanks were constructed.
One known way of providing secondary containment is to build a primary storage tank within a secondary tank structure, such that if the primary tank should develop a leak, the secondary tank will provide a second line of defence against liquid leakage into the surrounding environment. The present disclosure teaches an innovative process for constructing a primary open-top storage tank within a secondary containment tank without significant disturbance to the environment.
BRIEF SUMMARY
In general terms, the present disclosure teaches a dual-tank liquid storage system and methods for constructing such a liquid storage system, which comprises a lined primary storage tank disposed within a larger lined secondary tank. Construction of this dual-tank system typically involves the following steps:
An engineering base course is prepared over the ground area where the system is to be built, with the base course preferably being covered with a geotextile protective layer.
A flexible, impermeable liner for the secondary tank is then rolled out over the base course.
A flexible, impermeable liner for the primary tank is laid out over the secondary tank liner, with an outer portion being rolled up such that the partially rolled-up primary tank liner fits within the intended perimeter of the primary tank.
The perimeter wall of the primary tank is then site-assembled from a plurality of arcuate wall panel sections resting on the secondary tank liner, which is preferably protected by a liner protection material positioned over the secondary tank liner at the primary tank wall panel locations.
The rolled-up outer portion of the primary tank liner is unrolled and deployed up and over the fully-assembled wall of the primary tank.
An outer portion of the secondary tank liner is then rolled up so as to be temporarily disposed adjacent to the perimeter wall of the completed secondary tank.
The perimeter wall of the secondary tank is then site-assembled from a plurality of arcuate wall panel sections resting on the base course.
The rolled-up outer portion of the secondary tank liner is then unrolled and deployed up and over the fully-assembled wall of the secondary tank.
In the preferred embodiments illustrated and described herein, the primary and secondary tanks are generally circular in shape. In such embodiments, the primary and secondary tank wall panels are of arcuate configuration (in variant embodiments generally circular tanks could be constructed using wall panels that are substantially flat rather than arcuate). However, the methods taught herein can also be applied to the construction of dual-tank liquid storage tank system wherein either or both of the primary and secondary tanks may be of a non-circular configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments in accordance with the present disclosure will now be described with reference to the accompanying Figures, in which numerical references denote like parts, and in which:
FIG. 1 is a perspective view of a ground area that has been prepared for construction of a dual-tank liquid storage system in accordance with one embodiment of a method taught by the present disclosure.
FIG. 1A is a cross-sectional edge detail of the prepared ground area in FIG. 1 , illustrating a structural base course engineered to support liquid storage tanks.
FIG. 2 is a perspective view of a storage tank site as in FIG. 1 during the initial stages of construction of a dual-tank liquid storage system in accordance with one embodiment of a method taught herein, showing an outer tank liner laid out over the base course, a circular liner protection strip laid over the outer tank liner, and a partially deployed inner tank liner laid out over the outer tank liner.
FIG. 3 is a perspective view of a storage tank assembly under construction as in FIG. 2 , shown after erection of inner tank wall panels over a circular liner protection strip.
FIG. 4 is a perspective view of a storage tank assembly under construction as in FIG. 3 , illustrating the application of liner protection means over vertical joints between adjacent inner tank wall panels and at the interior circumferential juncture between the erected wall panel assembly and the outer tank liner.
FIG. 5 is a perspective view of a storage tank assembly under construction as in FIG. 4 , shown after the inner tank liner has been deployed over and secured to the inner tank wall assembly.
FIG. 6 is a perspective view of a storage tank assembly under construction as in FIG. 5 , illustrating the outer tank wall panels being erected over the base course.
FIG. 7 is a perspective view of a storage tank assembly under construction as in FIG. 6 , shown after the outer tank liner has been deployed over and secured to the outer tank wall assembly.
FIG. 8 is a perspective view of a representative pair of modular tank wall panels of the tank assembly illustrated in FIGS. 3-7 .
FIG. 9 is a perspective view of the vertical joint between an abutting pair of tank wall panels as in FIG. 8 , illustrating an exemplary and non-limiting example of a structural connection between the vertical edges of the abutting wall panels.
FIG. 10 is a vertical cross-section through a completed storage tank assembly as in FIG. 7 , shown with the inner tank filled with liquid.
DESCRIPTION
FIG. 1 illustrates a prepared ground surface 10 on top of which an engineered base course 20 has been constructed to provide stable ground support for a liquid storage tank assembly comprising a circular primary tank located generally concentrically inside a circular secondary tank in accordance with the present disclosure. Base course 20 will typically be a multi-layered soil structure, and as shown by way of non-limiting example in FIG. 1A may comprise a layer of compacted granular material 22 placed over ground surface 10 , then finished with a sand layer 24 which can be levelled and compacted to provide a smooth and dense surface.
In one embodiment, granular layer 22 may comprise at least a two inches of ½-inch (12.7 mm) crush compacted to at least 100% of Standard Proctor maximum dry density. However, the appropriate design and construction of base course 20 for a given installation will preferably be determined having regard to the geotechnical properties of the subsoil where the tanks are to be built. Base course 20 will preferably extend radially outward beyond perimeter of the secondary tank by a distance selected to geotechnical requirements and to provide adequate working space during tank construction. For example, for an embodiment of the dual-tank system including a 1.25 million USG (≈4.7 million liters) primary tank having a diameter of 135 feet (≈41 meters) and disposed within a secondary tank having a diameter of 148 feet (≈45 meters), base course 20 preferably will cover a circular area having a diameter of approximately 200 feet (≈61 meters).
Base course 20 is preferably covered with a base course protection layer 15 , which in one embodiment may be a double layer of a suitable geotextile.
As illustrated in FIG. 2 , the next step in the tank construction process is to provide a flexible, impermeable secondary tank liner 30 , sized and configured to cover the circular base area of the secondary (i.e., outer) tank and to extend upward and over the inside face of perimeter wall of the secondary tank. Secondary tank liner 30 is laid out over base course 20 (and base course protection layer 15 ) so as to cover a generally circular area within the intended circular perimeter of the secondary tank.
A suitable liner protection strip 52 is preferably provided over secondary tank liner 30 along a circular path corresponding to the intended perimeter of the primary tank, to provide a surface upon which the walls of the primary tank can be constructed without causing localized damage to the underlying portion of secondary tank liner 30 . Liner protection strip 52 may be provided in any form suitable for this purpose, such as (by way of non-limiting example) a double ring of geocomposite or geotextile material. In a preferred embodiment, liner protection strip 52 comprises a double layer of geotextile having a felt layer on the top and bottom.
Either before or after liner protection means 52 has been placed, a flexible, impermeable primary tank liner 40 , sized and configured to cover the circular base area of the primary tank and to extend upward and over the inside face of the perimeter wall of the primary tank, is laid out over secondary tank liner 30 so as to cover a generally circular area within the intended circular perimeter of the primary tank, but the outer portion 40 A of primary tank liner 40 that will ultimately be extended up and over the primary tank wall is rolled up like a tarpaulin such that the rolled-up wall portion 40 A is temporarily positioned a convenient distance radially inward from the intended perimeter of the primary tank. For example, for a primary tank having a diameter of 135 feet (≈41 meters), primary tank liner 40 will preferably be rolled out such that the diameter of rolled-up wall portion 40 A is approximately 90 feet (≈27 meters), in order to provide ample working clearance from the area where the primary tank is to be erected.
FIG. 3 illustrates a plurality of curved modular tank wall panels 62 that have been erected over liner protection strip 52 to form the walls of a primary tank 60 . Persons skilled in the art will understand that the erection of primary tank wall panels 62 may and typically will entail the use of temporary bracing (not shown) to stabilize panels 62 . Temporary bracing may be of any suitable type, and may be provided exterior and/or interior to wall panels 62 . Suitable protective means should be provided to protect secondary tank liner 30 from damage that might otherwise be caused by the installation of temporary bracing. In an alternative (and unillustrated) embodiment of the present tank system construction process, an outer portion of secondary tank liner 30 may be partially rolled up, with the rolled-up portion is positioned fairly close to the perimeter of primary tank 60 , such that exterior temporary bracing can bear directly onto base course protection layer 15 over base course 20 without impinging on secondary tank liner 30 . After all wall panels 62 have been erected to form an inherently stable primary tank 60 , all temporary bracing will be removed.
FIG. 4 illustrates the placement of liner protection strips 54 over vertical joints between adjacent primary tank wall panels 62 to protect against localized physical damage to wall portion 40 A of primary tank liner portion 40 when it is extended up and over wall panels 62 , such as liner damage that might occur as a result of movement across vertical joints between adjacent wall panels or panel misalignments due to fabrication and/or erection tolerances. For similar purposes, a continuous liner protection strip 56 is preferably placed along the interior perimeter of primary tank 60 where it rests upon secondary tank liner 30 over base course 20 . It should be understood, however, that liner protection strips 54 and 56 are not essential, and the practical need for same will typically be determined on a case-by-case basis subject to an assessment of the likelihood and potential significance of joint movements and/or tolerance issues.
FIG. 5 illustrates a completed primary tank 60 , with wall portion 40 A of primary tank liner 40 deployed to cover the inner surfaces of primary tank wall panels 62 and with an outer edge portion 40 B of primary tank liner 40 extending over the top of wall panels 62 and secured thereto by suitable removable clamp means 45 .
FIG. 6 illustrates a plurality of curved modular tank wall panels 72 being erected on top of base course protection layer 15 over base course 20 to form a secondary tank 70 . As shown in FIG. 6 , the outer portion 30 A of secondary tank liner 30 that will ultimately cover the inner surfaces of the secondary tank wall assembly has been rolled up so that it is inside the perimeter of secondary tank 70 , and preferably as close as possible to primary tank 60 to maximize the working room for erecting secondary tank 70 .
Although not illustrated, temporary bracing will typically be used during the erection of secondary tank wall panels 72 , generally as described above with respect to the erection of primary tank wall panels 62 . In cases where the radial distance between primary tank 60 and secondary tank 70 is not large (as in the illustrated embodiment), typically only exterior bracing will be used during the erection of secondary tank wall panels 72 . In alternative embodiments of the tank construction process, secondary tank wall panels 72 could also be temporarily braced against the completed primary tank structure 60 .
After all secondary tank wall panels 72 have been erected so as to form an inherently stable secondary tank 70 , all temporary bracing can be removed. Liner protection strips (not shown) may be placed over vertical joints between adjacent secondary tank wall panels 72 and along the interior perimeter of secondary tank 70 where it rests upon base course 20 , generally as described previously with respect to primary tank 60 .
FIG. 7 illustrates a completed secondary tank 70 , with wall portion 30 A of secondary tank liner 30 deployed to cover the inner surfaces of secondary tank wall panels 72 and with an outer edge portion 30 B of secondary tank liner 30 extending over the top of wall panels 72 and secured thereto by suitable removable clamp means 35 . The tank assembly is now ready to receive ancillary equipment and appurtenances (e.g., tank inlet and outlet piping; tank level gauges; catwalks and access platforms).
FIGS. 8 and 9 illustrate non-limiting examples of curved modular tank wall panels 62 (or 72 ), each comprising a horizontally-curved tank wall plate 63 ( 73 ) reinforced by a plurality externally-mounted, horizontally-curved structural stiffeners 64 ( 74 ), and with secondary vertical stiffeners 66 ( 76 ) extending between vertically-adjacent horizontal stiffeners 64 ( 74 ). The spacing of horizontal stiffeners 64 ( 74 ) preferably becomes smaller toward the bottom of wall panel 62 ( 72 ), thus reducing the vertical span of wall plate 63 ( 73 ) in order to minimizing wall plate thickness requirements while keeping flexural stresses in wall plate 63 ( 73 ) within safe limits as hydrostatic pressures exerted against wall plate 63 ( 73 ) increase toward the bottom of wall panel 62 ( 72 ).
An edge stiffener 65 ( 75 ) is provided along each vertical side edge of wall panel 62 ( 72 ). In the illustrated embodiment, and as shown in detail in FIG. 9 , edge stiffeners 65 ( 75 ) are provided with bolt holes for receiving bolts 68 which will be installed in the field to structurally connect adjacent wall panels 62 ( 72 ). However, the illustrated panel connection detail is by way of non-limiting example only, and persons skilled in the art will appreciate that wall panels 62 ( 72 ) can be structurally interconnected in various different ways, and that the selected structural connection details have no material bearing on the disclosed tank construction systems and concepts.
FIG. 10 illustrates the completed dual-tank system in operation, with primary tank 60 filled with liquid. In the event of a leak developing in primary tank liner 40 , any escaping liquid will be retained by secondary tank liner 30 within secondary tank 70 .
When the tank system is no longer needed on site, it is a simple matter to disassemble tanks 60 and 70 and to remove their respective liners 40 and 30 and all related components, by essentially reversing the various steps described above. The site can then be landscaped as desired to restore the site to a substantially natural and environmentally undisturbed condition.
It will be readily appreciated by those skilled in the art that various modifications to embodiments in accordance with the present disclosure may be devised without departing from the scope of the present teachings, including modifications using equivalent structures or materials hereafter conceived or developed. It is to be especially understood that the scope of the present disclosure is not intended to be limited to described or illustrated embodiments, and that the substitution of a variant of a described or claimed element or feature, without any substantial resultant change in functionality, will not constitute a departure from the scope of the disclosure.
In this patent document, any form of the word “comprise” is to be understood in its non-limiting sense to mean that any item following such word is included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one such element is present, unless the context clearly requires that there be one and only one such element.
As used herein, relative or relational terms such as but not limited to “vertical” are not intended to denote or require mathematical or geometric precision. Accordingly, such terms are to be understood in a general sense rather than a precise sense (e.g., “substantially vertical”), unless the context clearly requires otherwise.
Wherever used in this document, the terms “typical” and “typically” are to be understood in the sense of representative or common usage or practice, and are not to be understood as implying invariability or essentiality. | 4y
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BACKGROUND OF THE INVENTION
This invention relates to a circuit arrangement for operating a discharge lamp with a high frequency current comprising
input terminals for connection to a source of low frequency supply voltage,
rectifier means coupled to said input terminals for rectifying said low frequency supply voltage,
a first circuit comprising a series arrangement of first unidirectional means, second unidirectional means and first capacitive means coupled to a first output terminal N3 of said rectifier means and a second output terminal N5 of said rectifier means,
inverter means shunting said first capacitive means for generating the high frequency current,
a load circuit comprising a series arrangement of inductive means, second capacitive means and means for applying a voltage to the discharge lamp, said series arrangement connecting a terminal N1 of said inverter means to a terminal N2 between the first unidirectional means and the second unidirectional means, and
a second circuit comprising third capacitive means for connecting terminal N2 to terminal N5.
Such a circuit arrangement is known from U.S. Pat. No. 5,404,082. The known circuit arrangement is very suitable to be powered from a regular mains supply generating, e.g. a supply voltage having an r.m.s. voltage of 230 Volt and a frequency of 50 Hz. The known circuit arrangement has a relatively high power factor that is realized with comparatively simple means. A drawback of the known circuit arrangement is, however, that the total harmonic distortion of the current that is drawn from the source of low frequency supply voltage increases strongly if the means for applying a voltage to the discharge lamp does not comprise a transformer and the lamp voltage is relatively high. In case, for instance, the supply voltage has an r.m.s. voltage of 230 Volt, the harmonic distortion increases strongly for a lamp voltage higher than approximately 70 Volt. It should be mentioned that a similar problem exists even for discharge lamps having much lower values of the lamp voltage in countries like, for instance the U.S.A. where the supply voltage has an r.m.s. voltage of only 120 Volt. This harmonic distortion can be decreased by incorporating a transformer in the means for applying a voltage to the discharge lamp. In case, however, the lamp voltage is relatively high and the means for applying a voltage to the discharge lamp comprises a transformer equipped with a primary winding and a secondary winding provided with terminals for the lamp connection, both the primary winding and other components comprised in the load circuit and the inverter have to conduct a relatively large current. This relatively large current can shorten the life of the circuit arrangement or make it necessary to dimension the circuit arrangement in accordance with this relatively large current, which is expensive. Another drawback of the known circuit arrangement is that it is often necessary to include a frequency modulator in the circuit arrangement to modulate the frequency of the high frequency current generated by the inverter means to correct for amplitude modulations in this high frequency current and to control the crest factor of the lamp current to a value less than approximately 1.7.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a circuit arrangement that causes relatively little harmonic distortion of the low frequency supply current, while the circuit arrangement is also capable of operating discharge lamps having a relatively high lamp voltage without the drawback that components in the load circuit and the inverter have to conduct a relatively large current during lamp operation.
A circuit arrangement according to the invention is for this purpose characterized in that the first output terminal N3 of the rectifier means is connected to a terminal N4 between the second unidirectional means and the first capacitive means by means of a third circuit comprising a series arrangement of third unidirectional means and fourth unidirectional means. A terminal N7 between said third unidirectional means and said fourth unidirectional means is connected to a terminal N6 that is part of the load circuit by means of a fourth circuit and neither the first circuit nor the third circuit comprises inductive means.
During operation of the circuit arrangement the fourth circuit couples power from terminal N6 to terminal N7. It has been found that this power feedback, that is realized with relatively simple means, causes a substantial decrease in harmonic distortion when compared with the harmonic distortion caused by the known circuit arrangement. Correspondingly, the power factor increases substantially with respect to the power factor of the known circuit arrangement. Surprisingly, despite the feedback realized by means of the fourth circuit, in a circuit arrangement according to the present invention the current conducted by components in the load circuit and the inverter is relatively small, even in the case where the means for applying a voltage to the discharge lamp comprises a transformer. For this reason it is not necessary to dimension the inverter and the load circuit for a relatively large current and the load circuit and the inverter circuit can therefore be realized with relatively cheap components. Furthermore, it has been found that it is possible to dispense with a transformer in the load circuit of a circuit arrangement according to the invention and keep the harmonic distortion at a relatively low level at the same time, even in case the lamp voltage of the discharge lamp operated with the circuit arrangement is relatively high. In case the load circuit does not comprise a transformer, the amplitude of the current that flows through components of the inverter means and the load circuit during operation is further decreased with respect to circuit arrangements according to the invention comprising a transformer in the load circuit. Another important advantage of a circuit arrangement according to the invention is that a frequency modulator for modulating the frequency of the high frequency current can also be dispensed with, since it was found that the amplitude of the high frequency current generated by a circuit arrangement according to the invention is not strongly modulated and therefore the crest factor of the lamp current is relatively low. Both the modulator and more particularly the transformer are relatively expensive components so that the possibility to dispense with both in a circuit arrangement according to the invention is another reason why the circuit arrangement according to the invention has a relatively simple configuration and is therefore relatively inexpensive.
It also should be mentioned that a circuit arrangement comprising a double power feedback similar to the double power feedback in a circuit arrangement according to the present invention has been disclosed in EP 679046-A1. In the circuit arrangement disclosed in EP 679046-A1, the improvement of the power factor is mainly effected by making use of a storage coil. Such a storage coil is a rather expensive component. In a circuit arrangement according to the present invention a high power factor is achieved without making use of a storage coil. For this reason the functioning of a circuit arrangement according to the present invention differs from that disclosed in EP 679046-A1. Furthermore, a circuit arrangement according to the present invention offers a substantial advantage over the disclosure of EP 679046-A1 because in a circuit arrangement according to the invention the expensive storage coil can be dispensed with.
It has been found that a smooth operation of the circuit arrangement could be realized in the case where the second circuit further comprises the first capacitive means.
A smooth operation of the circuit arrangement was also found for configurations of the circuit arrangement wherein the fourth circuit comprises fourth capacitive means.
The unidirectional means preferably comprise diode means. The unidirectional means are thus realized in a very simple way.
In a preferred embodiment of a circuit arrangement according to the invention the inverter means comprise a series arrangement of a first switching element, terminal N1 and a second switching element, and a drive circuit DC coupled to the switching elements for generating a drive signal for rendering the switching elements alternately conducting and non-conducting. The inverter is thus realized in a relatively simple and dependable way.
It has been found that the circuit arrangement according to the invention is very suitable for operating two discharge lamps in parallel. In a preferred embodiment of a circuit arrangement according to the invention for operating two discharge lamps, the load circuit comprises a further series arrangement of inductive means, capacitive means and means for applying a voltage to a discharge lamp, and a terminal N8 that is part of the further series arrangement is connected to terminal N7 by means of a fifth circuit the fifth circuit preferably comprises fifth capacitive means.
In a further preferred embodiment of a circuit arrangement according to the invention terminal N4 is connected to terminal N7 by a circuit comprising a switching element S and a control circuit coupled to a control electrode of switching element S for rendering switching element S conductive and non-conductive. The control circuit renders the switching element S conductive when the lamp current is zero, for instance during preheating of the lamp electrodes or during ignition of the discharge lamp. An overvoltage across the first capacitive means is thereby prevented. After the discharge lamp has ignited the control circuit renders the switching element S non-conductive. The control circuit could for instance comprise means for detecting a lamp current. It has been found, however, that a very simple and dependable way to construct the control circuit is to equip said control circuit with means for rendering the switching element S conductive and non-conductive dependent upon the voltage across said first capacitive means.
BRIEF DESCRIPTION OF THE DRAWING
Embodiments of the invention will be explained in more detail with reference to the accompanying drawing, in which:
FIG. 1 is a simplified schematic diagram of a first embodiment of a circuit arrangement according to the present invention with a discharge lamp LA connected to the circuit arrangement;
FIG. 2 is a simplified schematic diagram of a second embodiment of a circuit arrangement according to the invention with two discharge lamps LA1 and LA2 connected to the circuit arrangement, and
FIG. 3 is a simplified schematic diagram of a third embodiment of a circuit arrangement according to the present invention with a discharge lamp LA connected to the circuit arrangement.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 K1 and K2 are input terminals for connection to a source of low frequency supply voltage. L2 and L2' are inductors that form an input filter together with capacitor C3. Diodes D1-D4 are rectifier means for rectifying said low frequency supply voltage. In this embodiment diodes D5 and D6 form first and second unidirectional means, respectively. Capacitor C4 is first capacitive means and forms together with diodes D5 and D6 a first circuit. Switching elements Q1 and Q2 together with a drive circuit DC form inverter means. Drive circuit DC is a circuit part for generating drive signals for rendering switching elements Q1 and Q2 conducting and non-conducting. Inductor L1, capacitor C2 and terminals K3 and K4 for connecting to a discharge lamp together form a load circuit. In the embodiment shown in FIG. 1 inductor L1 forms inductive means, capacitor C2 forms second capacitive means and terminals K3 and K4 for connecting to a discharge lamp form the means for applying a voltage to the discharge lamp. Capacitor C1 forms a third capacitive means. Capacitor C1 and capacitor C4 together form a second circuit. Diodes D7 and D8 form third and fourth unidirectional means, respectively. The series arrangement of diodes D7 and D8 forms a third circuit. Capacitor C5 forms fourth capacitive means and also a fourth circuit.
Input terminals K1 and K2 are connected by means of a series arrangement of inductor L2, capacitor C3 and inductor L2' respectively. A first side of capacitor C3 is connected to a first input terminal of the rectifier bridge and a second side of capacitor C3 is connected to a second input terminal of the rectifier bridge. A first output terminal N3 of the rectifier bridge is connected to a second output terminal N5 of the rectifier bridge by means of a series arrangement of diode D5, diode D6 and capacitor C4. N2 is a common terminal of diode D5 and diode D6. N4 is a common terminal of diode D6 and capacitor C4. Terminal N2 is connected to terminal N4 by means of capacitor C1. The series arrangement of diodes D5 and D6 is shunted by a series arrangement of diodes D7 and D8. N7 is a common terminal of diodes D7 and D8. Capacitor C4 is shunted by a series arrangement of switching elements Q1 and Q2. A control electrode of switching element Q1 is connected to a first output terminal of drive circuit DC. A control electrode of switching element Q2 is connected to a second output terminal of drive circuit DC. N1 is a common terminal of switching element Q1 and switching element Q2. Terminal N1 is connected to terminal N2 by means of a series arrangement of respectively inductor L1, capacitor C2, terminal K3, discharge lamp LA and terminal K4. N6 is a common terminal of capacitor C2 and terminal K3. Terminal N6 is connected to terminal N7 by means of capacitor C5.
The operation of the circuit arrangement shown in FIG. 1 is as follows.
When input terminals K1 and K2 are connected to the poles of a source of a low frequency supply voltage, the rectifier bridge rectifies the low frequency supply voltage supplied by this source so that a DC-voltage is present over capacitor C4 serving as a buffer capacitor. Drive circuit DC renders the switching elements Q1 and Q2 alternately conducting and non-conducting and as a result a substantially square wave voltage having an amplitude approximately equal to the amplitude of the DC-voltage on capacitor C4 is present at terminal N1. The substantially square wave voltage present at terminal N1 causes an alternating current to flow through inductor L1 and capacitor C2. A first part of this alternating current flows through terminals K3 and K4, the discharge lamp LA and terminal N2. The remaining part of this alternating current flows through capacitor C5 and terminal N7. As a result both at terminal N2 as well as at terminal N7 voltages having the same frequency as the substantially square wave voltage are present. These voltages present at terminal N2 and terminal N7 cause a pulsatory current to be drawn from the supply voltage source, also when the voltage on capacitor C4 is higher than the momentary amplitude of the rectified low frequency supply voltage. For this reason the power factor of the circuit arrangement has a relatively high value and the total harmonic distortion of the supply current is relatively low.
It should be mentioned that similar results were obtained for a configuration of the circuit arrangement slightly differing from the configuration shown in FIG. 1, where capacitor C1 connects terminal N2 to terminal N5 instead of to terminal N4. In this slightly different configuration capacitor C1 forms third capacitive means and a second circuit.
In a practical realization of an embodiment as shown in FIG. 1, the dimensioning was as follows: L1=905 μH, C5=5.6 nF, C1=18 nF, C4=11 μF, C3=220 nF and C2=180 nF, L2=1 mH and L2'=1 mH. With this embodiment a low pressure mercury discharge lamp with a nominal power of 58 Watt was operated. The lamp voltage of this lamp was 110 Volt. The frequency of the substantially square wave voltage was approximately 50 kHz and the power consumed from the low frequency supply voltage source was 52.3 Watt. The low frequency supply voltage source was a European mains supply supplying 230 Volts r.m.s with a frequency of 50 Hz. The lamp current was 452 mA r.m.s. The lamp current crest factor was 1.43. The current through the switching elements was 591 mA rms. The total harmonic distortion was less than 10%. It was found that when the same low pressure mercury discharge lamp was operated by means of a known circuit arrangement as described in U.S. Pat. No. 5,404,082 and equipped with a substantially identical input filter, a transformer was needed in the load circuit to keep the total harmonic distortion level at less than 10%. When the r.m.s value of the current through the low pressure mercury discharge lamp operated by means of the known circuit arrangement was approximately equal to 452 mA, the current through the switching elements was approximately 798 mA r.m.s. The r.m.s value of the current through the switching elements is thus 35% higher than when a circuit arrangement according to the invention is used.
The embodiment shown in FIG. 2 is to a large extent similar to the embodiment shown in FIG. 1. Similar components and circuit parts are indicated with the same reference signs in both figures. The load circuit of the embodiment of FIG. 2 comprises a further series arrangement of inductive means capacitive means, and means for applying a voltage to a discharge lamp, formed respectively by inductor L3, capacitor C6 and terminal K5 and terminal K6. A discharge lamp LA2 is connected to terminals K5 and K6. For clarity the discharge lamp connected to terminals K3 and K4 is indicated by LA1 in FIG. 2. Terminal K6 is connected to terminal K4. A terminal N8 between capacitor C6 and terminal K5 is connected to a first side of capacitor C7. A further side of capacitor C7 is connected to N7. Capacitor C7 forms in this embodiment both a fifth circuit and fifth capacitive means.
The operation of the embodiment shown in FIG. 2 is similar to that of the embodiment shown in FIG. 1 and will not be described separately.
The embodiment shown in FIG. 3 differs from the embodiment shown in FIG. 1 in that a switching element S connects terminal N4 to terminal N7. A control electrode of switching element S is coupled to an output terminal of circuitpart ST. In FIG. 3 this is indicated by means of a dotted line. Capacitor C4 is shunted by a series arrangement of resistor R1 and resistor R2. A common terminal of resistor R1 and resistor R2 is connected to an input terminal of circuitpart ST. The embodiment shown in FIG. 3 is also equipped with a means for preheating the electrodes of the discharge lamp La before ignition. These means comprise secondary windings L2 and L3 of coil L1 and capacitors C6 and C7. Each of the lamp electrodes is shunted by a series arrangement of a secondary winding and one of the capacitors C6 and C7.
The operation of the embodiment shown in FIG. 3 is as follows. Before the discharge lamp La has ignited, the lamp electrodes are preheated during a predetermined time lapse by rendering the switching elements conductive and non-conductive at a frequency at which the impedance of capacitors C6 and C7 is relatively low. Both during this preheating as well as during the ignition phase, the amplitude of the voltage across capacitor C4 increases to a value that is higher than the value during stationary operation of the discharge lamp. This higher amplitude is caused by the fact that the lamp current is zero while power is fed back via capacitor C5. The voltage at the input terminal of circuit part ST is proportional to the voltage on capacitor C4. When the voltage over capacitor C4 reaches a first predetermined value the circuit part ST renders switching element S conductive so that diode D8 is shortcircuited, whereby a further increase of the voltage across capacitor C4 is prevented. When after the ignition of the discharge lamp the amplitude of the voltage on capacitor C4 drops below a second predetermined value (lower than the first predetermined value) the circuitpart ST renders switching element S non-conductive so that power feedback via capacitor C5 is activated. The operation of the embodiment shown in FIG. 3 during stationary operation is identical to that of the embodiment shown in FIG. 1 and will not be further described. | 4y
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BACKGROUND
The invention relates to agricultural planters, such as hoe openers and seeding tools used in farming operations to distribute seeds into soil. Generally, openers are towed behind a tractor via a mounting bracket secured to a rigid frame of the tractor. These openers may include a ground engaging tool or opener that forms a seeding path for seed deposition into the soil. The ground opener is used to break the soil to enable seed deposition. After the seed is deposited, the opener may be followed by a packer wheel that packs the soil on top of the deposited seed. The packer wheel may be rigidly mounted behind the opener via a structural member or rear frame. Thus, the opener and packer wheel generally move together with the same upward and downward motion.
Unfortunately, existing openers do not adequately address the need to accommodate height variation over terrain during seeding or transportation without seeding. It is generally undesirable to pull the hoe opener through soil when merely transporting the opener from one location to another. In addition, during seeding, existing openers do not provide adequate vertical motion of the opener and related assembly without compromising the load on the opener and packer wheel. As a result, variations in the terrain can result in substantial changes in the packing force (e.g., normal force) of the packer wheel on the terrain being seeded by the opener and the draft force of the terrain on the opener. The variable force on the opener can result in loss of control over seeding depth. More specifically, this variation in packing and opener force can result in non-uniform seeding depths and packing density in the terrain being seeded by the planter.
Existing openers also require substantial force to raise the planter row unit, including the opener assembly and packing wheel. This results in the use of large hydraulic cylinders to raise the apparatus, due to the overall length and weight of each planter row unit. This hydraulic equipment is costly and takes resources (i.e. hydraulic power) from other portions of the tractor and planter unit.
There is a need, therefore, for improved arrangements in precision hoe openers and planters that improve accuracy of the seeding operation. There is a particular need for planters and openers that apply forces to the opener and the packing wheel to improve seeding depth and accuracy.
BRIEF DESCRIPTION
The present invention provides a novel configuration for precision hoe opener assemblies. This configuration of the opener assembly provides improved accuracy of seeding as well as improved control over the opener and packer wheel assemblies. In an exemplary embodiment, the opener assembly includes a hydraulically-driven parallel linkage assembly. The parallel linkage is coupled to the hoe opener and the packer wheel, and is configured to apply a substantially constant force in a deployed position. These features enhance seeding accuracy, especially during changes in the elevation of terrain. In addition, the configuration enables the hydraulic cylinder to raise the hoe opener and the packer wheel above the ground. The design may be implemented for agricultural planters as well as other implements or applications requiring control of height and/or force of implements.
DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
FIG. 1 is a perspective view of a precision hoe opener assembly in accordance with aspects of the invention, including an opener, a packer wheel, and a parallel linkage assembly;
FIG. 2 is a side view of the opener assembly of FIG. 1 , showing the opener implement and packer wheel assemblies in a deployed position;
FIG. 3 is a top view of the opener assembly from FIGS. 1 and 2 ; and
FIG. 4 is a perspective view of an entire planter assembly system, including multiple opener assemblies and the tool bars that they are attached thereto.
DETAILED DESCRIPTION
Turning now to the drawings and referring first to FIG. 1 , an embodiment of a precision hoe opener assembly is illustrated and designated generally by reference numeral 10 . As will be appreciated by those skilled in the art, hoe opener assembly 10 is a type of row unit, which may be placed on an agricultural implement, such as a planter. Precision opener assembly 10 includes a frame support 12 , mounting brackets 14 , first member 16 , second member 18 , and a linear actuator such as a cylinder 20 (e.g., hydraulic and/or pneumatic piston-cylinder assembly). Cylinder 20 may be hydraulically coupled to a power supply 22 that is used to provide a flow of pressurized hydraulic fluid that displaces a piston rod extending from the cylinder. Precision hoe opener assembly 10 may be towed, or generally moved by a vehicle, such as a tractor. For example, the frame support 12 and frame bracket 14 may interface tool frame tow bar connected to the tractor (not shown) for towing the precision hoe opener assembly 10 . For instance, a plurality of opener assemblies 10 may be mounted in parallel along a tool frame bar to comprise a planter unit. Elements 12 , 16 , 18 , 36 and 20 may be collectively described as components of a hydraulically driven parallel linkage assembly. The parallel linkage assembly may also be referred to as a four bar linkage. As will be appreciated by those skilled in the art, components of opener assembly 10 , such as frame support 12 , mounting brackets 14 , first member 16 , and second member 18 , may be made of any suitable material, such as steel or an alloy.
Cylinder 20 is attached to a shank adapter 24 via a pin at the end of the piston rod. The shank adapter 24 is also coupled to shank 26 and opener 28 . Shank adapter 24 may be coupled to shank 26 via fasteners 30 , which allow height adjustments of opener 28 , enabling a variable seeding depth for the opener assembly. Pin 32 is coupled to first member 16 and shank adapter 24 , allowing shank adapter 24 to pivotally rotate about the pin 32 as cylinder 20 extends and retracts. Accordingly, opener 28 moves downward or upward based upon cylinder 20 's extension or retraction, respectively. Shank adapter 24 may feature several holes to receive a pin coupling the end of cylinder 20 to the adapter. The adapter holes may be used to adjust the angle of cylinder 20 with respect to the parallel linkage assembly, thereby changing the angle and magnitude of cylinder forces.
As cylinder 20 retracts, stop plate 34 may press on rear frame 36 , creating a lifting force that is conveyed to packer wheel assembly 38 . The resulting lifting force, caused by cylinder 20 , reduces the packing force of wheel 40 and may eventually lift packing wheel 40 from the terrain. In the embodiment, packer wheel assembly may allow height adjustment of packer wheel 40 , in the form of fastener and slot or an equivalent structure. In some cases, the resulting lifting force may compensate for an increased packing force, caused by terrain elevation changes, thereby increasing seeding accuracy. To facilitate seed deposition during operation, opener 28 is coupled to a seed distribution header 42 via a seeding tube 44 .
FIG. 2 illustrates a side view of an embodiment of the precision hoe opener 10 . The figure illustrates the precision hoe opener 10 in a neutral position on generally level terrain. Further, as the terrain elevation fluctuates, the hoe opener position will move upward or downward from the neutral position. Cylinder 20 is extended, thereby deploying the opener 28 downward into the terrain, pressing shank adapter 24 against rear frame stops 46 . In the present context, the deployed position may be used to describe the precision hoe opener 10 in a ground-engaging, working position where the shank adapter 24 is pressed against rear frame stops 46 and opener 28 is engaged with the terrain. For example, while in a deployed position the opener 10 may vertically travel up to eight inches as the opener 28 goes over and maintains contact with the contours of a terrain. During sharp changes in elevation, the opener 28 is maintained at a substantially constant angle with the terrain by the parallel linkage and the expansion and contraction of cylinder 20 . In this deployed position, cylinder 20 also exerts a downward force on packer wheel 40 . When cylinder 20 retracts, opener 28 is lifted from the deployed position, as indicated by arrow 48 . When in the fully retracted position, stop plate 34 presses against contact surface 50 , lifting packer wheel 40 upward. As the opener assembly 10 retracts fully, opener 28 and packer wheel 40 are lifted from terrain 52 . The fully retracted position may be utilized when transporting the planter between fields, to minimize wear and tear of the opener.
As will be appreciated by one skilled in the art, the configuration of shank adapter 24 , first member 16 and rear frame 36 allows the actuator to pivotally move shank 26 and opener 28 through an angular range independently of packer wheel assembly. That is, in the range of motion between stop plate 34 and rear frame stops 46 , shank adapter 24 and cylinder 20 cause only movement of the opener 28 . In the embodiment, while the opener 28 and actuator 20 are in this “independent” range of motion, the precision hoe opener may not be in a deployed position, i.e. the opener 28 may be removed from contact with the ground. Further, this movement of the opener 28 directly changes the angle between opener 28 and the terrain. In contrast, when in a deployed position, the opener 28 and the terrain are maintained at a substantially constant angle by the parallel linkage assembly. The arrangement may also be helpful as the hoe opener 10 encounters large clods or trash and the actuator 20 is retracted, the shank adapter is released from contact with the frame stops 46 , lifting opener 28 , thereby reducing wear or damage that may be caused by such impediments.
A top view of the precision hoe opener assembly 10 is illustrated in FIG. 3 . The figure shows cylinder 20 , first member 16 , second member 18 , shank adapter 24 , and rear frame 36 . The embodiment illustrates that pin 32 is used to couple and control movement of many components of opener assembly 10 , including first member 16 , rear frame 36 , and shank adapter 24 . The view also illustrates that packer wheel assembly 38 places packer wheel 40 directly behind the opener 28 .
Referring back to FIG. 2 , the opener assembly 10 and opener 28 are depicted in a deployed position. During normal operation in a deployed position, opener 28 may break through terrain 52 creating a draft force on opener 28 . In this deployed position, a cylinder load is directed along the cylinder 20 and cylinder rod to shank adapter 24 , manipulating packer wheel 40 and opener 28 with a generally constant downward force. In particular, the geometry of the illustrated parallel linkage, including first member 16 , second member 18 , frame support 12 , and rear frame 12 , results in a generally constant downward force on opener 28 and packer wheel 40 as the terrain elevation fluctuates.
In general, the drawing illustrates that the precision opener assembly 10 has an increased range of motion providing a generally constant packing force to the soil. This is achieved in part by the opener assembly 10 maintaining a substantially constant angle between packer wheel assembly 38 and terrain 52 . In addition, the geometry of the hydraulically driven parallel linkage assembly, including elements 12 , 16 , 18 , and 20 , allows the opener assembly to maintain the substantially constant packing force and the substantially constant orientation with respect to the terrain.
As will be appreciated by those skilled in the art, the disclosed embodiments of precision opener 10 provide control of the packing force and the seeding depth by controlling opener 28 and packing wheel 40 . The opener 10 advantageously responds to variations in the terrain, draft force on the opener 28 , the packing force, or a combination thereof. Thus, the opener 10 can provide a generally uniform packing force and seeding depth to improve the overall quality of the seeding process, and in turn improve subsequent growth originating from the seeds. Again, the hoe opener 10 has a variety of adjustment mechanisms to control the location of the packer wheel 40 , the opener 28 , or a combination thereof.
FIG. 4 illustrates the agricultural implement assembly, including a plurality of precision opener assemblies 10 , as row units of a complete agricultural planter system 54 , as may be towed behind a tractor (not shown).
While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | 4y
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This application is a continuation application of International application No. PCT/AT2009/000348, filed Sep. 7, 2009, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention concerns an actuating device with at least one actuating member for moving a movable furniture part and a locking device for inhibiting a movement of the actuating member.
The invention further concerns an article of furniture having at least one actuating device of the kind to be described.
Such actuating devices are fixed in particular to the carcass of an article of furniture, wherein the actuating device is provided to move an upwardly movable flap.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to propose an actuating device of the kind referred to in the opening part of this specification, which allows a controlled movement of the actuating member.
According to the invention, the object is achieved in that the locking device has a lock which is arranged in or on the actuating device and which is unlockable by a key for enabling the movement of the actuating member.
In a first aspect of the invention, only an authorized person (or possibly also a plurality of authorized persons) is allowed access to the possibility of moving the actuating member. The lock can be both unlocked by the key and also—if desirable—locked.
If the actuating device is pre-fitted in or on the article of furniture and the movement of the actuating member is to be inhibited in the closed position of the movable furniture part, it may be desirable to provide on the article of furniture a through opening which allows the key to be fitted through from a position outside the article of furniture into the lock arranged on or in the actuating device. It will be appreciated that it is also in accordance with the invention to use a key-lock system which functions in contact-less fashion. For that purpose the key can include for example an electronic data set and/or a contact-lessly operating RFID transponder.
A further aspect of the invention provides that the proposed locking device with the lock and the key is used as an assembly securing means for the “vacant” actuating member, in which case therefore a movable furniture part—in particular an upwardly movable furniture flap—is not yet fitted to the actuating member. Those actuating devices serve to move a furniture flap fitted to the pivotably mounted actuating member (in particular an actuating arm) between a vertical position of closing a compartment in a carcass of an article of furniture, and an upwardly moved open position. A spring device or a gas compression storage means is used to compensate for the weight of the flap, in which case the torque acting on the actuating member can be selectively adjusted to the weight of the furniture flap to be moved. In the case of heavy furniture flaps therefore a relatively high torque is to be provided as the biasing force for the actuating arm. If however a furniture flap has not yet been pivotally connected to the actuating arm, there is a serious risk that the actuating arm can move rapidly upwardly severely in the opening direction under the force of the spring device acting thereon, and can thereby injure the fitting personnel. WO 2006/069412 A1 to the present applicant already discloses a fitting securing means for the “vacant” actuating arm—on which therefore a furniture flap has not yet been fitted—which has a latching and/or braking device for limiting the opening speed of the vacant actuating arm.
The spring device acts on the actuating member—which is preferably pivotable about a horizontal axis—in the opening direction, and there is a considerable risk of injury caused by an actuating member which strikes out upwardly, when the flap has not yet been fitted. Accordingly, the present invention allows the actuating member to be arrested in its completely open position by the locking device having the lock and the key. The actuating member cannot therefore be moved against the force applied by the spring device, by virtue of the locking action. That permits the flap to be fitted without any problem to the actuating member which is arrested in the completely open position.
In an embodiment of the invention it can be provided that the key is secured by a releasable holding device on or in the actuating device and the releasable holding device releases the key only after the flap has been fitted to the actuating member. In other words the key is available to release the locking action only when the flap has been properly fitted to the actuating member. When the flap is securely fixed to the actuating member then the risk of an actuating member lashing out upwardly is also substantially eliminated. It is only after the flap has been fitted that the releasable holding device releases the key, whereupon the locking device can be unlocked and then the actuating member is movable unimpededly between a closed position and an open position.
In accordance with an additional safety aspect of the invention it can be provided that the key unlocks the locking device only as long as the key is fitted in the lock. In other words the actuating member is freely movable only with a key fitted in the lock. When the key is removed from the lock, the locking device can automatically block a movement of the actuating member.
The actuating device usually has a power path which in the simplest case includes the actuating member and the spring device acting on the actuating member. In that case the locking device locks at least one element of that power path, that is to say the spring device and/or the actuating member. It will be appreciated that it is also possible for the power path to have a transmission mechanism (either a lever mechanism and/or a gear assembly), which acts between the spring device and the actuating member, wherein at least one element of the transmission mechanism is lockable by the locking device. In this connection it can be provided that the locking device has at least one arresting element by which the element of the power path is lockable relative to a part which is fixed with respect to the article of furniture—preferably the housing of the actuating device. In that respect it may be desirable if the arresting element is movable by the key from a position of arresting the element of the power path into a release position in which the arresting element is unlocked from the element of the power path.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of the present invention will be described by means of the specific description hereinafter, which reference to the figures in which:
FIGS. 1 a , 1 b show a side view of an actuating device mounted to a furniture carcass for moving an upwardly movable furniture flap, wherein the actuating member of the actuating device is arrested in the completely open position by a locking device, and an enlarged detail view thereof,
FIGS. 2 a , 2 b show the locked actuating device with a furniture flap already fitted to the actuating member, and an enlarged detail view thereof,
FIGS. 3 a , 3 b show the actuating device with a locking mechanism unlockable by a key and an enlarged detail view thereof,
FIGS. 4 a - 4 c show various views of a fixing device provided for connection to the furniture flap,
FIGS. 5 a - 5 c show vertical sections of the fixing device in temporal successions in respect of key unlocking, and
FIGS. 6 a - 6 d show various views of the locking device arranged in or on the actuating device and provided for arresting an element of the power path of the actuating device, in an arresting position and in a release position.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 a shows a side view of an actuating device 1 according to the invention having a housing 2 which is pre-fitted to a side wall 4 a of a furniture carcass 4 . The actuating device 1 in known fashion has a spring device 3 which is supported on the one hand against a mounting 3 a , which is fixed with respect to the article of furniture, on the housing 2 , and which on the other hand acts on the actuating member 5 in the form of an actuating arm 5 a , about the axis of rotation R, in the opening direction. Arranged between the spring device 3 and the actuating arm 5 a is a transmission mechanism in the form of an intermediate lever 6 (movable element) mounted pivotably about an axis of rotation S. It is also possible to see a locking device 7 which in the illustrated embodiment locks the intermediate lever 6 and inhibits it from a pivotal movement about the axis of rotation S. The actuating member 5 in the form of the actuating arm 5 a can be arrested in its completely open position by locking of a movable element of the transmission mechanism in the power path (in the present case the intermediate lever 6 ). That locking device 7 is therefore part of a fitting securing means for the “vacant” actuating arm 5 a to which therefore no furniture flap is pivotably connected. Locking of the actuating arm 5 a in its completely open position means that it cannot be urged in the direction of the closed position. That has the advantage on the one hand that a furniture flap can be connected without any problem to the actuating arm 5 a which is arrested and thus held in a stable condition. On the other hand the actuating arm 5 a can also not be urged in the direction of the closed position as—in particular due to lack of attention—it can uncontrolledly slip out of an intermediate position preceding the completely open position and by virtue of the extremely high prestressing forces of the spring device 3 can move rapidly back into the completely open position again and as a result can cause massive injury. The actuating member 5 in the form of the actuating arm 5 a has a fixing device 8 for releasable connection to a fitment at the hinge side (not shown), whereby a furniture flap can be connected to the actuating arm 5 a . It is also possible to see a diagrammatically illustrated key 9 which is secured by a releasable holding device on or in the fixing device 8 . The key 9 which is necessary for unlocking the locking device 7 cannot however be removed when the flap is not fitted in place. The key 9 can only be released from the fixing device 8 when a flap is properly connected to the fixing device 8 . It is only after the flap has been fitted to the actuating arm 5 a that the key 9 is released and can then be passed to the locking device 7 , whereby the locking action is releasable and the actuating arm 5 a is pivotable between the closed position and the open position.
FIG. 1 b shows an enlarged view of the region circled in FIG. 1 a . It is possible to see the pivotable intermediate lever 6 which is acted upon by the spring device 3 . The spring device 3 presses against the intermediate lever 6 at a spring mounting 10 , wherein the position of the spring mounting 10 is variably adjustable by an adjusting device 11 relative to the intermediate lever 6 . In that way the force of the spring device 3 can be selectively adjusted to the weight of the flap which is still to be mounted in place. The locking device 7 includes a lock 7 a into which the key 9 can be inserted after the flap has been fitted (at a right angle to the plane of the drawing), whereby the arresting element 7 c of the locking device 7 is unlockable from the intermediate lever 6 . When the arresting element 7 c is released from the intermediate lever 6 the actuating arm 5 a can also move unimpededly again.
FIG. 2 a shows the arrangement of FIG. 1 a , wherein the fixing device 8 of the variable-length actuating arm 5 a is properly connected to a fitment 13 associated with the furniture flap 12 . When therefore the correct connection is made between the fixing device 8 and the fitment 13 at the flap side, the key 9 is also released, as indicated in the Figure. The intermediate lever 6 is still arrested in the illustrated view, but the locking device 7 is releasable from the intermediate lever 6 by the key 9 which has now been released. The flap 12 in the illustrated embodiment is in the form of a two-part flap 12 having flap portions 12 a and 12 b . The upper flap portion 12 a is mounted pivotably relative to the furniture carcass 4 while the lower flap portion 12 b is mounted pivotably by way of a connecting fitment (not shown) relative to the upper flap portion 12 a . In the closed position the two flap portions 12 a and 12 b assume a vertical position and in so doing substantially completely cover the compartment of the furniture carcass 4 . FIG. 2 b shows a view on an enlarged scale of the region circled in FIG. 2 a with the locking device 7 in the blocking position, the arresting element 7 c being latched to an arresting element 6 a associated with the intermediate lever 6 .
FIGS. 3 a and 3 b show the unlocked locking device 7 , wherein the key 9 released in FIG. 2 a has been fitted into the lock 7 a of the locking device 7 . By virtue of the key 9 being fitted into the lock 7 a of the locking device 7 , as shown in FIG. 3 b , the arresting element 7 c has been pivoted and released from the arresting portion 6 a of the intermediate lever 6 . The intermediate lever 6 can now be pivoted about axis of rotation S whereby a pivotal movement of the actuating arm 5 a is also possible again.
FIG. 4 a shows a perspective view of the fixing device 8 provided for releasable connection to the fitment 13 , at the flap side, which is shown in FIGS. 2 a and 3 a . It is possible to see the key 9 which is releasable from the fixing device 8 only after the flap has been fitted. FIG. 4 b shows an exploded view of the fixing device 8 which has a holding device 14 for the key 9 . The holding device 14 includes a movable coupling portion 14 a having a latching element 14 b which in the locked position is latched to a corresponding latching element 9 a of the key 9 so that the key 9 is arrested relative to the holding device 14 . It is possible to see a holding element 15 which is associated with the fixing device 8 and which has a displaceably mounted actuating element 15 a provided for acting on the coupling portion 14 a . The movable pin-shaped actuating element 15 a is more specifically urged in the direction of the illustrated arrow Y upon fitment of the flap 12 , whereby the coupling portion 14 a is moved about the axis 14 c and the latching element 9 a of the key 9 is released. The holding element 15 includes a support portion 15 c which is resilient or which is acted upon by a spring and which is latchable to the fitment 13 at the flap side. It is also possible to see a pivotable securing portion 16 which arrests the support portion 15 c when the key 9 is pulled off. In that way it is not possible to release the support portion 15 c when the key 9 is pulled out, from the arresting position with the fitment 13 on the flap side. FIG. 4 c shows a side view of the fixing device 8 with the secured key 9 . In a variant of the invention it can also be provided that the key 9 is also secured by way of a releasable holding device 14 at the fitment 13 at the flap side.
FIGS. 5 a - 5 c each show vertical sections of the fixing device 8 in temporal successions in respect of key unlocking. It is possible to see the coupling portion 14 a pivotal about the axis 14 c . In FIG. 5 a the latching element 9 a of the key 9 is in engagement with the corresponding latching element 14 b of the coupling portion 14 a so that the key 9 cannot be pulled out. The displaceable, pin-shaped actuating element 15 a bears against the coupling portion 14 a . It is possible to see the resilient support portion 15 c and its securing portion 16 which is in a release position in the illustrated Figure. A flap 12 has not yet been fitted in FIG. 5 a.
In FIG. 5 b the fixing device 8 is connected to a flap 12 by way of the fitment 13 at the flap side. The resilient support portion 15 c is latched with the fitment 13 . By virtue of that fitting procedure the actuating element 15 a is also moved downwardly by a contact surface of the fitment 13 whereby the coupling portion 14 a has been pivoted about the axis 14 c . The result of this is that the latching element 14 b of the coupling portion 14 a has been unlocked from the latching element 9 a of the key 9 so that the key 9 can now be pulled out.
FIG. 5 c shows the withdrawn key 9 . In this respect it is also to be stated as a particularity here that after the key 9 has been pulled out of the fixing device 8 the securing portion 16 was pivoted under spring force in the direction of the support portion 15 c so that manipulation of the support portion 15 c is not possible. Release of the flap 12 is only possible when the key 9 is inserted into the fixing device 8 again whereby the securing portion 16 is pivoted back again so that the support portion 15 c is actuable and is movable out of the arresting position with the fitment 13 on the flap side.
FIG. 6 a shows the locking device 7 which can be unlocked by the key 9 and which is or can be arranged on the housing 2 of the actuating device 1 . The locking device 7 includes housing portions 17 a and 17 b , wherein the lock 7 a is formed by the intermediate space remaining between the housing portions 17 a , 17 b . The arresting element 7 c is in the form of a double-armed lever pivotable about an axis M. The arresting element 7 c is acted upon by a spring (not shown) which holds the arresting element 7 c in the arresting position with the intermediate lever ( FIG. 1 b ). When the key 9 is pushed into the lock 7 a the latching element 9 a of the key 9 presses against a lever arm of the arresting element 7 c ( FIG. 6 c ) so that the arresting element 7 c pivots about the axis M and thereby releases the intermediate lever 6 .
FIG. 6 b shows the locking device 7 in the assembled condition. FIG. 6 c shows a vertical section through the locking device 7 with inserted key 9 , the latching element 9 a of which presses against a lever arm of the arresting element 7 c . The locking action is removed in that position so that the actuating arm 5 a can move. FIG. 6 d shows a vertical section with the key 9 removed. FIG. 6 d shows the empty lock 7 a , wherein the arresting element 7 c is automatically urged by spring force in the direction of the arresting position and in the fitted condition blocks an element of the power path of the actuating device 1 .
The present invention is not limited to the illustrated embodiment but includes or extends to all technical equivalents which can fall within the scope of the claims appended hereto. The positional references adopted in the description such as for example up, down, lateral and so forth are also related to the directly described and illustrated Figure and are to be appropriately transferred to the new position upon a change in position. | 4y
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This invention is directed to an air-blast deflector for a specific type of lug-removing pneumatic gun having forwardly-directed air-blast air-exhaust ports.
THE PRIOR ART
While there is no known prior art relating to an air-deflector for laterally-directing forward air-blast from a pneumatic gun, the lug-removing pneumatic impact-gun of the type to which the inventive air-deflector is directed, is typically the particular lug-removing Ingersol Rand Air Pneumatic tool models 231 and/or 231-2 each of which are currently manufactured and commercially available at this time, and which have spaced-apart left and right forwardly-directed exhaust-air ports, these model pneumatic tools producing adjustable torque ranging from about 120 to 140 foot-pounds of torque. For the utility to which the present invention is directed, a minimum torque of at-least about 140 foot-pounds is required, at the high no. 5-position setting of those pneumatic tools. The closest prior art patent to the lug-removing pneumatic-gun impact tool of the type to which the present invention is directed, is the Fleigle U.S. Pat. No. 3,823,795 exhibiting in its FIG. 1 a pneumatic gun having forwardly positioned and directed air-blast exhaust ports.
BACKGROUND
The particular air-blast pneumatic impact guns of the typical above-noted types of Ingersol Rand Air Pneumatic tool models 231 and/or 231-2 to which the present invention is specifically directed, is a well-known particular type of lug-removing impact pneumatic gun for which the molds and parts and machining thereof is well established and developed. The design has proven to be well accepted commercially and accordingly continues in present commercial production and is expected to continue into the indefinite future.
However, in the use of the particular lug-removing pneumatic impact guns having the forwardly-directed air blast of the exhausting air thereof, workers in the use thereof to remove lugs from wheels of trucks and/or automobiles and/or other industrial vehicles, have been and continue to be confronted with a serious health hazard to their eye and to their lungs and upper respiratory sinuses and the like, as a direct result of the concentrated and high-intensity forwardly blasting air disrupting asbestos dust and other dirt and debris associated with such wheels and lugs. The asbestos dust and/or dirt and/or debris are air-lifted and impacted into the face and/or eyes and/or nose and/or mouth of the worker removing the wheel lugs by use of the particular lug-removing pneumatic impact gun. As a result of the critical requisite of an exceptionally high-level of impact of at-least about 140 foot-pounds of torque as above-noted for the present invention use in a lug-removing combination of the particular lug-removing pneumatic impact tool, critically the exhaust ports of the gun must remain free of obstructions such as filters, mufflers or the like that inherently would throttle the impact tool power sufficiently to render the tool inoperative for purposes of removing lugs of vehicular wheels--noting that it is not infrequent that such lugs are "frozen" as a result of long use and high temperatures during their use on the wheel(s) such that lesser torque impact pressures (foot pounds of torque) would totally fail to adequately serve required needs for the particular lug-removing pneumatic impact tools to which the present invention is directed. In that sense, the sound-muffler of the above-noted Fleigle U.S. Pat. No. 3,823,795 would critically defeat the utility of the present invention because of inherent back-pressure caused by such device that results in significant and fatal reduction in maximum achievable foot pounds of torque of the particular lug-removing pneumatic impact gun to which the present invention is directed.
It has become recently recognized that continuous exposure to dust and dirt, particularly where such often contains asbestos dust or particles from worn brakes, is potentially carcenogenious and is additionally recognized to constitute a serious threat or potential problem to the sensitive eyes and/or sinus and/or respiratory organs of a worker when blown into the face of the worker attempting to remove the wheel lugs.
THE OBJECTS
The present invention is directed avoiding and/or lessening and/or overcoming such problems.
Another particular object is directed to minimizing the cost or expense to the manufacturer or user of corrective structures for the above-identified particular lug-removing pneumatic impact guns required for the vehicle-wheel lug-removing technology, such that advancement of improved safety and reduction of health hazard will be desirable and readily providable by either or both the manufacturer and/or the consumer because of the simplicity and low cost of the present invention.
Another object is to achieve one or more preceding objects by a novel structure of simple and easy and low-cost manufacture.
Another object is to achieve one or more preceding objects by virtue of a simple and small object easily handled and mountable on lug-removing pneumatic impact guns of the particular types above-discussed, by either or both the manufacturer and/or consuming end-user, such that prolific or wide-spread use thereof will readily reduce health hazards to large segments of the using-public population of workers.
Other objects become apparent from the preceding and following disclosure.
One or more of the objects of this invention are achieved by the invention and disclosed and claimed herein.
BROAD DESCRIPTION OF THE INVENTION
Broadly in the light of the foregoing background and objects, the invention may be characterized as a lug-removing pneumatic impact-gun air blast-deflector for laterally diverting forwardly directed exhaust air blast on the particular lug-removing pneumatic impact guns of the types above-described, having forwardly-directed air-blast exhaust ports, for the particular lug-removing pneumatic impact having forwardly-directed air-blast exhaust or outlet ports. It is noted that for these particular models or types of lug-removing pneumatic impact tool-guns forwardly-directing the air-blast thereof during their use, downward diversion is unacceptable because the high intensity air quickly freezes the finger(s) associated with the trigger of the pneumatic gun, in the small available trigger space. Also, the inventive structure is and must be likewise critically devoid of insert or throttling-down structure(s) in the air outlet or exhaust ports that would materially or significantly block the exhaust port(s) and/or that would interfere with use of the trigger and/or constitute structure on which the hand or finger could be struck or injured and/or which would get in the way of handling or moving-about the tool within limited working space. It is in the light of foregoing background problems together with these considerations that add to the critical nature of the present invention and its structural shape together with its susceptability to easy mounting onto and detachability from the particular above-described lug-removing pneumatic impact gun. Accordingly the present inventive air-blast deflector includes an air-blast deflector structure and mechanism thereof that is mountable on the particular impact lug-removing pneumatic gun which gun is structured to blast exhaust air forwardly. The air-blast deflector structure and mechanism thereof is/are formed, manufactured and/or shaped such that it is mountable on the particular lug-removing pneumatic impact gun in a position adapted to intercept forwardly-blasted exhaust air and to redirect the forwardly-blasted exhaust air to at-least one lateral direction, noting that the air blast deflector of this invention does not detrimentally cause any significant air back-pressure to any extent that detrimentally interferes with or reduces the essential minimum number of foot pounds of torque pounds. Thereby and accordingly, forwardly-directed exhaust air blast from the particular lug-removing pneumatic impact gun is prevented from blasting forwardly-located debris. The air-blast deflector structure and mechanism thereof is/are easily detachably mountable onto the particular lug-removing pneumatic impact gun.
In a preferred embodiment, the above-described invention further includes the particular lug-removing pneumatic impact gun having the inventive air-blast deflector structure and mechanism thereof mounted thereon, as a novel combination.
In another preferred embodiment, the invention includes the air-blast deflector structure and mechanism thereof including a substantially vertically positionable flange having a lower forward edge adapted to be mounted by a housing-bolt of the particular lug-removing pneumatic impact gun positioned to exhaust its air blast substantially vertically forwardly, and also includes a deflector baffle extending horizontally rearwardly from and integral with a lower forward edge when the flange is vertically positioned and mounted on the particular lug-removing pneumatic impact gun. As a result of such inclusions, the flange extends substantially along a transverse plane relative to a longitudinal axis of a forwardly-directed air blast outlet of the lug-removing pneumatic impact gun whereby at least one unobstructed substantially laterally-extending air flow path is formed along which forwardly directed air-blast is laterally divertable when exhausting from the particular lug-removing pneumatic impact gun. In this embodiment, more preferably the vertically positionable flange includes aperture-forming structure forming a through-space aperture of a size and positioned to receive a forwardly-positioned housing bolt of the particular lug-removing pneumatic impact gun produceable of a forwardly-directed air-blast. Also in this embodiment, more preferably the deflector structure and mechanism thereof further includes oppositely-extending first and second first and second portions extending in substantially opposite lateral directions; each of the first and second portions include substantially a laterally-extending half of each of the vertically positionable flange and the downwardly-positioned substantially horizontally rearwardly-extending deflector baffle whereby at-least two oppositely-extending unobstructed substantially laterally-extending air flow paths are formed along which forwardly directed air-blast is divertable for exhausting from the particular lug-removing pneumatic impact gun. Also in this embodiment, the deflector baffle preferably includes oppositely-extending left and right deflectors on each of opposite sides of a centerline location, each deflector including a proximal portion located in juxtaposition to the centerline location and a distal portion angled obliquely upwardly and rearwardly at about a 25 to 55 degree angle, typically at about 40 degrees. Also, this embodiment preferably includes the particular lug-removing pneumatic impact gun having said air-blast deflector mounted thereon, as a novel combination. Optionally or in addition, the invention includes the deflector structure and mechanism thereof including at least one deformable plate bent along said forward edge to form and position each of the above-noted vertically positionable flange and the above-noted horizontally rearwardly-extending deflector baffle. More preferably the vertically positionable flange includes aperture-forming structure forming a through-space aperture of a size and positioned to receive a forwardly-positioned housing bolt of a pneumatic gun produceable of a forwardly-directed air-blast; optionally and preferably, another preferred embodiment of the invention includes the particular lug-removing pneumatic impact gun having its air-blast deflector thereby mounted thereon as a novel combination.
In an alternate embodiment, the deflector structure and mechanism thereof includes a single unitary plate of predetermined thickness. A rearward partially machined-away upper portion of a secondary thickness less than the predetermined thickness as said vertical positionable flange, and also includes therebelow a residual residual-portion) retaining substantially its full-thickness [substantially equal to (substantially the same as) the predetermined thickness as the forwardly-positioned substantially horizontally rearwardly-extending deflector baffle. More preferably, the vertically positionable flange includes aperture-forming structure forming a through-space aperture of a size and positioned to receive a forwardly-positioned housing bolt of a pneumatic gun produceable of a forwardly-directed air-blast. In another preferred embodiment, there is included the particular lug-removing pneumatic impact gun having the air-blast deflector mounted thereon as a novel combination.
THE FIGURES
FIG. 1A diagrammatically illustrates one preferred embodiment of the inventive deflector structure and mechanism thereof, shown in an inverted position, as a front view thereof with regard to the position thereof when mounted on the particular lug-removing pneumatic impact gun above-described.
FIG. 1AA diagrammatically illustrates the same embodiment and inverted front view as that of FIG. 1, except that in this illustration, the deflector structure and mechanism thereof is shown prior to the bending of the deflector baffle to its horizontally rearwardly extending position relative to the vertical positionable flange carrying the bolt-mounting hole.
FIG. 1B diagrammatically illustrates an inverted back view of the same embodiment as that of FIG. 1.
FIG. 1B' diagrammatically illustrates a right-side view as taken along lines 1B'--1B' of FIG. 1B, the deflector structure and mechanism thereof here being shown tilted-over 90 degree, not being in an actual mounting upright-position as it would be viewed from the right side of the gun when mounted on the particular lug-removing pneumatic impact gun above-described, as shown is below described FIG. 1C.
FIG. 1B" diagrammatically illustrates a bottom inverted view as taken along lines 1B"-1B" of FIG. 1B, this illustrated bottom-viewed position not being the upright actual position as it would be viewed from the front view when uprightly mounted on the particular lug-removing pneumatic impact gun above-described as shown in the below described FIG. 1D.
FIG. 1C diagrammatically illustrates a side view of the novel gun-combination of the novel air-blast deflector structure and mechanism thereof of FIGS. 1A, 1AA, 1B, 1B', and 1B" in a mounted-position in the side-viewed position as contrasted to the illustrated 90 degree tilted-over view in above-described FIG. 1B'.
FIG. 1D diagrammatically illustrates a front view of the deflector structure and mechanism thereof of above-described FIGS. 1A, 1AA, 1B, 1B', 1B" and 1C, in a mounted position illustrated in above-described FIG. 1C illustrating the same front view as FIG. 1A for the deflector structure and its mechanism.
FIG. 2A diagrammatically illustrates an alternate preferred embodiment of the inventive deflector structure and mechanism thereof, shown in an inverted position, as a front view thereof with regard to the position thereof when mounted on the particular lug-removing pneumatic impact gun above-described.
FIG. 2B diagrammatically illustrates an inverted back view of the same embodiment as that of FIG. 1.
FIG. 2C diagrammatically illustrates a side view of the novel gun-combination of the novel air-blast deflector structure and mechanism thereof of FIGS. 2A, and 2B, in a mounted-position in the side-viewed position.
FIG. 2D diagrammatically illustrates a front view of the deflector structure and mechanism thereof of above-described FIGS. 2A, 2B and 2C, in a mounted position illustrated in above-described FIG. 2C illustrating the same front view as FIG. 2A for the deflector structure and its mechanism.
DETAILED DESCRIPTION
FIGS. 1A, 1AA, 1B, 1B', 1B", 1C and 1D are each and all directed to different view-illustrations of the same common embodiment. Accordingly, to the extent that these different Figures illustrate common elements, the indicia are identical.
FIGS. 2A, 2B, 2C and 2D are each and all directed to an alternate related embodiment illustrating different views of the alternate embodiment. Accordingly, to the extent that the alternate embodiment illustrates substantially corresponding structure of substantially corresponding functions as contrasted to the embodiment of FIGS. 1A and the like, the indicia are related, to facilitate understanding of the similarity in the alternate embodiment. To the extent that elements are the same in different views of this alternate embodiment, indicia of the alternate embodiment in the different illustrations thereof are likewise identical to one another.
Once a particular indicia has been identified as to name and function thereof for either embodiment, description thereafter is not repeated for different view nor for the other embodiment, except in some cases in order to facilitate or improve understanding and an improved ease of following meaning in the description of the invention.
As above noted, the present invention includes in one form thereof, the deflector structure and mechanism thereof considered alone, for use on any particular lug-removing pneumatic impact gun as above-identified. In another form, apart from other preferred and alternate embodiments of the inventive deflector structure and mechanism thereof, another form of the invention is the novel combination inclusive of the particular lug-removing pneumatic impact gun itself as a further novel and inventive combination, achievable of a result not heretofore possible.
The above-described deflector structure and mechanism thereof of this invention is easily installable onto the particular lug-removing pneumatic impact gun above-described, namely typically the Ingersol Rand Air Pneumatic tool currently identified by that company as models 231 and 231-2. Use of the inventive most preferred embodiments of the different alternate embodiments of the invention, allow (cause) the blast of air from the respective left and right exhaust ports thereof to be discharged laterally to the opposite sides of the air pneumatic tool above-noted, instead of being discharged forwardly, i.e. instead of being discharged straight-out toward and against miscellaneous debris previously discussed above. The inventive deflector structure and mechanism thereof can be easily installed on the old models already in the hands of the consuming public, and/or can be installed during manufacture before sale of the resulting novel combination, by mere use of the same forwardly-positioned bolt/screw that for years has been used and is currently still used on this particular lug-removing pneumatic impact-gun air blast-deflector. It is merely required that the forwardly-positioned bolt (screw) as hereinafter identified, be removed, inserted through the through-space screw/bolt aperture of the deflector structure and mechanism thereof, and reinserted within the gun's forward-receiving bolt/screw aperture (receptacle) and a tightening thereof, with the resulting mounting of the novel inventive defector structure and mechanism of the present invention, to result in the novel gun-combination thereof.
Accordingly, the invention may be better understood by reference to the following indicia description of elements thereof for the different above-noted Figures.
In FIG. 1A, there is shown in an inverted state, the embodiment 3 having the vertically positionable flange 7 as left and right flanges 7a and 7b (left and right, as they would be positioned and mounted on the above-described, particular, lug-removing pneumatic impact gun), the bottom right and left edges 7aa and 7bb, the left and right top edges 12a and 12b, and the bolt-receiving through-space hole 10 formed in the vertically positionable flange intermediate between the left and right flanges 7a and 7b.
FIG. 1AA illustrates the same embodiment 3 structure and features as that of FIG. 1A, also illustrated in the inverted position relative to its normal mounting position, except here illustrating a view as it would appear prior to the final bending and/or forming and/or molding in the final-shaped state as bent or formed or molded with a 90-degree bend along the above-described lower edges (lower edges when positioned for or after mounting on the particular above-described gun) 7aa and 7bb between the vertically positionable flanges 7a and 7b and the horizontally-rearwardly positionable deflector baffles-proximal portions 8a and 8b. Also shown are the rearwardly upwardly angularly positionable right and left deflector baffles-distal portions 8aa and 8bb angled obliquely upwardly and rearwardly as positioned when mounted on the particular above-described gun. Also shown, is the recessed or slotted-structure between the lower edges 7aa and 7bb, allowing the forward edges 7aa and 7bb to be slightly angled upwardly (as described relative to the position when mounted on the particular above-described gun) along sideward portions thereof, when bent along the illustrated dotted-line representing the locations of the forward edges 7aa and 7bb.
FIG. 1B in its back view of the same embodiment 3 shows the same elements above-described for FIG. 1AA, except additionally showing the positions of the respective oppositely laterally-extending left and right diverted air-blast channels 11a and 11b as they would be located when the embodiment 3 is mounted on the particular air gun as illustrated in respective FIGS. 1C and 1D.
FIG. 1B' illustrates for the embodiment 3 the same elements and features as described for preceding Figures of the embodiment 3, except better illustrating the right upwardly angle sidewardly-extending bottom distal portion 8b relative to the more downwardly-positioned centerline location of the indented or slot location 9 in the mounted position typically shown in FIG. 1C.
FIG. 1B" illustrates for the embodiment 3 the same elements above-described, except better illustrating the relative locations of the respective above-described elements to one another in this bottom view as it would be viewed in the mounted state and position as typically shown in FIG. 1C.
FIG. 1C illustrates the novel gun-combination 5 in a right-side view of the combination, in addition to elements previously described, better showing their relationships to the particular above-described gun. Additionally, the otherwise conventional and currently commercially available above-described particular lug-removing pneumatic impact gun 13 is illustrated as to conventional parts/elements thereof such as the lug-engaging element 19 and the forward plate 15 mounted by the forward bolts/screws inclusive of the lower forward bolt/screw 16, the handle 17, the gun-actuation trigger 18, the torque-impact adjustment adjustable switch 20 for adjusting between low and high impact positions 21 ranging from zero-impact position to the highest torque impact position 5, illustrating typical positions ranging from zero up to position 5 often and normally present, noting that for lug-removing purposes it is normally necessary and critical to have the gun set at the maximum torque position number 5. Also shown is forwardly-positioned gun portion 23. Also shown in phantom dotted lines is the typical prior art pneumatic air-providing line 22 as it would be positioned and mounted to the gun.
FIG. 1D illustrates the same elements as previously described, except additionally showing in the cut-aways the forwardly-directed right and left gun blast-air exhaust vents 14aa and 14bb, as well as showing corresponding left-side elements described only for right-side elements in FIG. 1C, such as right and left portions 15a and 15b of the front plate (edge) 15, and the right and left bottom portions 23a and 23b of the forwardly-extending gun portion 23 of FIG. 1C.
FIG. 2A there is shown in an inverted state, the embodiment 4 having the vertically positionable flange 7' as left and flanges 7'a and 7'b (left and right, as they would be positioned and mounted on the above-described particular lug-removing pneumatic impact gun), the bottom right and left edges 7'aa and 7'bb, the left and right top edges 12'a and 12'b, and the bolt-receiving through-space hole 10' formed in the vertically positionable flange intermediate between the left and right flanges 7'a and 7'b.
FIG. 2B in its back view of the same embodiment 4 shows the elements corresponding to those described in above-described for FIG. 1AA and to some extent in FIGS. 2A and 1A, including the machined portions 7'a and 7'b that have the secondary remaining lesser thickness as compared to the above-described predetermined thickness retained by the unground (unmachined) portions 8'a and 8'b, and the thereby formed positions of the respective oppositely laterally-extending left and right diverted air-blast channels 11'a and 11'b as they would be located when the embodiment 4 is mounted on the particular air gun 13' as illustrated in respective FIGS. 2C and 2D.
FIG. 2C illustrates the novel gun-combination 6 in a right-side view of the combination, in addition to elements previously described, better showing their relationships to the particular above-described gun. Additionally, the otherwise conventional and currently commercially available above-described particular lug-removing pneumatic impact gun 13', the elements thereof corresponding to elements described-above for gun 13 of the gun-combination 5 of FIG. 1C as to the conventional parts/elements thereof.
FIG. 2D illustrates for the embodiment 4 the same elements as previously described, except additionally showing in the cut-aways corresponding to those described for embodiment 3 of FIG. 1D, here for the embodiment 4 showing the forwardly-directed right and left gun blast-air exhaust vents 14'aa and 14'bb, as well as showing corresponding left-side elements described only for right-side elements in FIG. 2C, such as right and left portions 15'a and 15'b of the front plate (edge) 15', and the right and left bottom portions 23'a and 23'b of the forwardly-extending gun portion 23' of FIG. 2C.
As should apparent from the preceeding disclosure and descriptions thereof, to mount the vertically positionable flanges 7 or 7' through the bolt or screw-receiving apertured hole 10 or 10' thereof, the bolt or screw 16 or 16' is simply removed from it position of mounting the plate 15 or 15', the aperture-hole 10 or 10' is merely matched with the correspondingly positioned bolt or screw-receiving hole (not shown) in the plate 15 with the deflector vertically positionable flanges 7 or 7' extending upwardly against the gun forwardly-extending portions 23a and 23b or 23'a and 23'b, and thereafter inserting the bolt or screw 16 or 16' through the hole 10 or 10' and tightening the bolt or screw to tightly secure the plate 15 or 15' and the mounted above-described blast deflector of this invention, as typically shown in the novel mounted combinations of FIGS. 1C and 1D and 2C and 2D.
It is within the scope of the invention to make such variations and substitution of equivalents and modifications as would be apparent to a person of ordinary skill in this particular art. | 4y
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FIELD OF INVENTION
[0001] The present invention relates to the size controlled and stabilized nano-aggregates of molecular ultra small clusters of noble metals and a process for the preparation thereof. Particularly the present invention relates to the single source multicolor noble metal spherical and uniform nano aggregates of 10-22 nm made up of discrete molecular ultra small noble metal (Nb) nanoclusters (MUSNbNC's) of 1-6 atoms. The MUSNbNC's are capped with amine/DCA (dicarboxy acetone) group acting as a steric and kinetic hindrance for core growth suppressing the further autocatalysis and conversion of super critical nucleus or growth by ripening and formation of nanoparticles and thus having intense fluorescence. The invention more specifically relates to gold/silver/platinum 10-22 nm spherical nano aggregates capped and stabilize at fringes with amine or DCA along with the oxyethylene group. The molecular ultra small clusters in a discrete form and controlled size of these Nano aggregates thus shows the quantum confinement effect. Hence, these noble metal nano clusters are having potential applications in biomedical like UV & photo therapy, in case of cutaneous lymphoma, biosensing, biolabeling/bioimaging applications. The 10-22 nm nano aggregates of discrete MUSAuNC's after capping with mercaptoundeconic acid (MUDA) shows increase in fluorescent emission by 6 times and which are stable at 3-4 acidic pH and at room temperature (˜25°)
BACKGROUND OF THE INVENTION
[0002] Bio-sensing requires surface functionalization to detect a particular target molecule or ion. The surface has to be uniform, consistent and should have an ability to get modified without altering the original properties with respect to a target ion or molecule to be detected. Uniformity is of utmost importance for unconstrained and clutter-free binding of the target bio-molecule; small size, non toxicity to use as a fluorescent probe. These properties are important in achieving sensitivities of the order of 10 −8 -10 −9 M, especially in the case of piezo-electric sensors and also as a florescent chip as many metal ions plays vital role at extremely low concentrations during patho-physiology. The principal aim was dynamic utilization of noble metal particles with single domain synthesis and sample preparation.
[0003] Gold Nano Particles (AuNPs) are potential candidates for the development of nano-bio-sensors, diagnostic and therapy as they have been widely used in understanding the biological processes and also in diversified biomedical applications. AuNP's have attractive features such as, inert, easy and versatile surface chemistry to modify, biocompatibility negligible toxicity and researchers have gained enough experiences in synthesizing different size and shapes of AuNP's in controllable manner. Further, AuNP's are having very high sensitivity towards biomolecule, tuned SPR/luminescent, retention of bioactivity and opportunity for 3D imaging are important characters as a fluorescent probe/marker. Reliable and high-yielding methods for the synthesis of AuNP's, including those with spherical and non spherical shapes, have been developed over the last century. It is necessary to synthesize the nanomaterial for bioconjucation which can be universally used as a tracer as well in therapy. The very small nanoparticles, clusters and nanoroads shows visible to IR fluorescence. However small nanoparticles, clusters and nanorod's shows some form of toxicity. As the size increases due to the autocatalysis they convert to form the stable super critical nucleus showing surface plasmon; 5-25 nm particles shows the surface plasmon at 510-540 nm (Concha Tojo et al; Materials; 2011, 4, 55-72) and diminishing the fluorescent property, as the fluorescence is the function of molecule like electronic structures and quantum confinement effect which is observed in very small nanoparticles. (Tatsuya Tsukuda, Bull. Chem. Soc. Jpn., 2012, 85 (2), 151-168).
[0004] Ref made to Beatriz Santiago Gonzalez et al: ACS Nano lett. 2010, 10, 4217-4221 where Nonoclusters of gold particles capped with PVP is reported. Due to the weak bonding of PVP mass spectra only shows the peak related to Au 2 and Au 3 and the theoretical calculation using the Jellium model shows fluorescence emission at 293 nm and 336 nm which are related to clusters of Au 2 and Au 3 . It showed UV (300 to 400 nm) emission from Au 2 to Au 11 PVP clusters however such small clusters are difficult to characterize and handle to utilize in any kind of applications. In the present invention the surface capped nano aggregates of ultra small clusters which are also stabilized by amine or DCA of reducing agent and hindering the further growth having luminescent properties of quantum clusters with size of 10-22 nm and shows UV emission at 300-335 nm, no plasma resonance and 2 nd order visible emission at 590-650 nm resemble to the nanoparticles or super critical nucleus are mentioned.
[0005] However recently, numerous studies have shown that size and capping agent of nanoparticles play an important role in cellular uptake and cytotoxicity; (B. Devika Chithrani and W. C. W. Chan; ACS Nanolett. 2007, 7(6), 1542-1550; Yu Pan; Willi Jahnen Dechent; Small, 2007, 3(11), 1941-1949 and Catherine J. Murphy; J Nanopart Res; 2010, 12, 2313-2333); X. D. Zhang et al; biomaterials; 2012, 33, 6408-6419) they have also shown that 10-27 nm size range of AuNP are most biocompatible and having negligible toxicity. Another problem with the small gold nano crystals is toxicity and difficulty in handling the very small size nano clusters. It was reported that 1.4 nm diameter particles were toxic, whereas 15 nm diameter particles were nontoxic, even at up to 100-fold higher concentrations. Particles above 5 nm are non fluorescent. Nanorod's are having the SPR and also the luminescence near IR and potential candidates for photothermal therapy against cancer but shows the toxicity by formation of reactive oxygen species (Nicole M. Schaeubin etal ACS, langmuire 2012, 28, 3248-3258). QD's are excellent probe due to distinctive quantum confinement effect and tunable and high photo luminescence however its toxic effects are of serious concern especially for bioapplications. (Francoise M. Winnik et al; ACS accounts of chemical research; 2013, 46 (3), 672-680).
[0006] Walter H. Chang et al; J. Medcal and biological Engg.; 2009, 29(6), 276-283 shows the blue, green and red emission by using the various capping agent and etching the NP's and final size of these nanocluster lies in the range of 1-3.5 nm however being very small they may lend the toxic effect.
[0007] Huan-Tsung Chang et al; Anal Chem.; 2008, 80, 1497-1504 synthesized 2.9 nm brightly luminescent MUDA capped Au nanodots which are stable for three months when stored in dark and at 4° C. Review by Didier Astruc et al; Chemi rev.; 2004, 104; 293-346 showed the aggregation of MUDA capped AuNP in acidic condition. C. A. J. Lin et al ESBME-Peter; AuNP capped with MUDA using tetraborate buffer, 9.2 pH. AuNP's 3.1 nm capped with MUDA shows the agglomeration when synthesized at room temperature as compared the cold synthesis (Mark T. Swihart, Colloids and Surfaces A:Physicochem Eng. Aspects 2004. 246; 109-113).
[0008] Alexander Gaiduk etal; publication no. WO 2012028936 A1 and application number: PCT/IB2011/002003 showed the green and red emission by using the organic solvent and photo thermal microscopy showed the enhancement in fluorescence in solid state. They coated the glass surface with glycerol. Fluorescence was not observed when water was used. However we do not have any such kind of restrictions, instrumentation and no photo-thermal therapy was needed. The particles are fluorescent in both solid and liquid state.
[0009] These problems are of a great challenge if the AuNP's are to be used in biological systems especially in vivo applications. Hence, there have been many attempts to tailor make the process.
[0010] Aniruddha S. Deshpande et al; Nanoscale res. lett.; 2008, 3, 221-229; synthesized Sulphur nanoparticles with an average size of 10 nm using the oil phase and 15 (vol.%) aqueous phase contains iron chelate and the H 2 S gas was used as a precursor.
[0011] Jun Lin et al; materials letters; 2001, 49, 282-286; synthesized AuNP using 0.056 M HAuC14 and 0.32 M NaBH 4 using CTAB/octane reverse micelle and stabilized with dodecanethiol resulted in the formation of 1D, 2D and 3D superstructures.
[0012] Even after continuous research there are long standing problems limiting the full utilization of AuNC's like uniform size clusters, their thermo dynamical stability as clusters are having the tendency to grow further. Moreover, once the clusters reach to critical size they formed supercritical nucleus and grow further until the growth is arrested by capping agent. Once they form the supercritical nucleus they loose the property of luminescence and surface plasmon is dominated. Another difficulty is water soluble and isolable nanocrystals/nanoparticles (Kyosti Kontturi etal; ChemPhysChem; 2006, 7, 2143-2149). We have overcome both the hurdles; the 10-22 nm globular aggregates stabilized with amine group of hydrazine hydrate or dicarboxyacetone of citric acid or capped with mercaptopropionic acid or MUDA can be easily extracted by centrifugation and re-dispersed in water. Stability at low pH is desirable for drug delivery especially AuNP's capped with MUDA, mercaptoundeconic acid which in general are stable only in highly basic pH 9-13. Huan-Tsung Chang (Anl. Chem. 2008, 80, 1497-1504) showed stabilization at low pH by reducing tempt. to 4° and storing in dark; is again a limitation. The stability at low pH 3.5 MUDA capped 10-22 nm globular nano aggregates has the potential to replace the toxic PEG/bifunctional PEG (high cost) which at presently used for the drug delivery and many other bio-applications, also shows some form of toxicity. (Xiao-Dong Zhang et al). The 10-22 nm globular aggregates can be used dynamically in various bio applications including drug delivery.
[0013] These problems make the use of gold nanocrystals/nano dots restrictive in biological systems, especially for in vivo applications. Further, according to some studies Ramsay D L, Arch Dermatol. 1992 July; 128(7):931-3 possible protective role for UV-β therapy has been suggested in case of cutaneous T-cell lymphoma and immuno-regulatory. UV-β irradiating in geriatric patients increase the level of 25-hydroxyvitamin D levels (B. L. Diffy, Phys. Med. Biol.; 1980, V. 25 (3), 405-426). UV-β therapy was also used for skin disorders like lupus and sepsis; against infection of antibiotics resistance strains etc (Dr. Jonathan V. Wright: Harnessing the healing power of light Part 1). In such cases also role of desirable size of AuNP's/AuNC's or AgNP/AgNC's with selective UV-β luminescence is contemplated wherein it may be applied locally on the affected area.
[0014] Hence, there is a long standing need of prior art of AuNC's of controlled aggregate of 10 nm to 22 nm size which are biocompatible, non-toxic, capable of UV-β and visible emissions which may be used dynamically for various biomedical applications like UV and, phototherapy, drug delivery, biosensing, bio-labelling/bioimaging applications simultaneously. Also, the fluorescence remains unchanged in solid state for both as synthesized amine/DCA capped as well as after capping with MUDA/MPA.
[0015] The emission energy decreases with increasing number of atoms. The inventor has attempted to overcome the limitations of prior art and disclosed narrow size distributed, photo stable, multicolour fluorescence and capped globular nano aggregates (of size 10-22 nm) made up of 2-6 atoms ultra small clusters (encapsulated in a matrix of amine/dicarboxyacetone) with the functional group amine or carboxyl extractable and dispersed in water; capable of UV emission at 300-335 nm+/−5 nm; visible emissions: green emission when blue/green filter was used and 590-650 nm 2 nd order red emission; no plasmon resonance at 500-550 nm. These 10-22 nm size aggregates of atomic quantum ultra small nanoclusters which by virtue of the larger aggregate size (10-22) are safer than individual atomic nanoclusters/nanoparticles of 1-5 nm (Yu Pan, Willi Jahnen Dechent; Small, 2007, 3(11), 1941-1949), while at the same time retaining the optical properties of fluorescence which is the characteristics of atomic quantum 1-5 nm nanoclusters/nanoparticles (Beatriz Santiago Gonzalze et al: ACS Nanolett. 2010, 10, 4217-4221). Such aggregates can be the excellent fluorescent probe including for cell imaging both in vivo and in vitro, sensing and therapy. By virtue of the intense fluorescence which can replace the toxic semiconductor quantum dots etc.
OBJECTS OF THE INVENTION
[0016] The main object of the present invention is to provide nano aggregates of molecular nano clusters of noble metals and a process for the preparation thereof.
[0017] Another object of the present invention is to provide narrow size distributed, photo stable multicolour fluorescence, capped and spherical nano aggregates (size range of 10-22 nm) made up of 1-6 atoms stable clusters (embedded in amine/DCA) and also MUDA capped with UV emission at 300-335 nm and visible emission (green when use blue or green filter) red emission at 590-650 nm.
[0018] Another object of the present invention is to provide nano aggregates which are not showing the surface plasmon resonance which is the characteristic of ultra small clusters. Another object of the invention is to provide spherical nano aggregates (USMNCs) capped with mercaptoundecanoic Acid (MUDA) which are stable at pH 3-4 at RT (˜25) and having 6 times enhanced fluorescent emission.
[0019] Yet another object of the invention is to provide a process for the preparation of nano aggregates which are non-toxic, biocompatible and surface can be modified by ligand exchange to append with MUDA or with another mercaptan ligand.
SUMMARY OF INVENTION
[0020] Accordingly, the present invention provides capped spherical nano aggregates of size 10-22 nm comprising molecular ultra small clusters of 1-6 atoms of noble metals selected from the group consisting of Au, Ag, Pt and Pd, and said clusters of 1-6 atoms being stabilized by a capping agent forming, d nano aggregates showing UV emission at 300-335 nm, no plasma resonance and visible 2 nd harmonic emission at 590-650 nm.
[0021] In one embodiment of the present invention, capping agent used is a mild reducing agent selected from the group consisting of hydrazine hydrate or citric acid in water.
[0022] In an embodiment of the present invention, the surface of nanoaggregates is stabilized and capped by amine or dicarboxyacetone (DCA) of a mild reducing agent along with the oxyethylene group.
[0023] In another embodiment of the present invention, mercapto undecanoic acid is used as a capping agent by ligand exchange of amine or dicarboxyacetone.
[0024] In another embodiment of the present invention, mercapto undecanoic acid capped nano aggregates are stable at pH 3-4 at room temperature ranging between 25-35° C.
[0025] Still in another embodiment of the present invention, mercapto undecanoic acid capped nano aggregates show 6 times more floresecence intensity in comparison to amine/dicarboxyacetone capped nano aggregates.
[0026] Still in another embodiment of the present invention, nanoagregates show green emmission when blue or green filters are used.
[0027] Still in another embodiment of the present invention, a process for the preparation of spherical nano aggregates, wherein the said process comprising the steps of;
a) preparing a oil phase by stirring cyclohexane and non ionic surfactant Triton 100-X (C14H22O(C2H4O)n (n=9-10) in ratio ranging between 52:22 wt. % to 54:24 wt % for 11-12 hrs at room temperature ranging between 25-35° C. with constant stirring and adding 7-11 wt. % n hexanol into it and stirring further for 10-12 hrs at room temperature ranging between 25-35° C.; b) dividing oil phase as obtained in step (a) into two equal parts; c) adding aqueous solution of freshly prepared 0.056 M metal salt in one part of oil phase as obtained in step (b) and stirring for 10-12 hrs; d) adding aqueous solution of freshly prepared 0.32 M mild reducing agent in second part of oil phase as obtained in step (b) and stirring for 10-12 hrs; e) combining solution as prepared in step (c) into the solution as obtained in step (d) dropwise and further stirring the solution for a period ranging between 10-20 days at room temperature ranging between 25-35° C. to obtain solution containing nanoaggregates; f) centrifuging solution containing nanoaggregates as obtained in step (e) at 5000-6000 rpm for 10-20 min. at room temperature ranging between 25-35° C. and washing with water and ethyl alcohol 2-3 times to obtain spherical nano aggregates.
[0034] Still in another embodiment of the present invention mild reducing agent used in step (d) is selected from the group consisting of hydrazine hydrate or citric acid in water.
[0035] Still in another embodiment of the present invention metal salt used in step (c) is Auric Chloride, Silver nitrate and Platinum Chloride.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0036] FIG. 1 shows a schematic representation of capped at fringes with amine or DCA along with oxyethylene group stabilizing the spherical nano aggregates of noble metal (Nb); consists of molecular ultra small nano clusters embedded in amine or DCA acting as a steric hindrance for further growth and stabilizing the clusters kinetically (nano aggregates of MUSNbNC).
[0037] FIG. 2 shows spectroscopy of Nano aggregate of MUSAuNC's reduced with Hydrazine hydrate (HH) (a) UV-absorption spectra; (b) Florescence spectra; excitation at 230 nm.
[0038] FIG. 3 shows fluorescence microscopy of Nano aggregate of MUSAuNC's reduced with HH a) UV filter b) Green filter c) Red filter
[0039] FIG. 4 shows HRTEM/TEM of nano aggregate of MUSAuNC's reduced with HH (a) HRTEM, after 1 st wash; morphology high mag. (b) core microemulsion droplet containing coalescent droplets and particles inside it; TEM low mag.
[0040] FIG. 5 shows HRTEM/TEM of Nano aggregate of MUSAuNC's reduced with HH, (a) Morphology (HRTEM), low magnification with crystalline diffraction rings; (b) high magnification of core microemulsion droplet containing coalescent droplets and particles therein; TEM.
[0041] FIG. 6 shows mass analysis of nano aggregate of MUSAuNC's reduced with HH (a) freshly extracted (b) after 6 months storage in emulsion.
[0042] FIG. 7 shows FTIR spectra of Nano aggregate of MUSAuNC's reduced HH (a) MidIR (b) FarIR.
[0043] FIG. 8 shows XPS spectra of Nano aggregate of MUSAuNC's reduced with HH.
[0044] FIG. 9 shows spectroscopy of Nano aggregate of MUSAuNC's reduced with citric acid (CA) (a) UV-absorption (b) Photoluminescence spectra (excitation at 290 nm).
[0045] FIG. 10 shows HRTEM and Fluorescence Microscopy of Nano aggregate of MUSAuNC's reduced with CA (a) Morphology (b) Fluorescence with Carl Zeiss Bio AFM using blue filter.
[0046] FIG. 11 shows spectroscopy of Nano aggregates of MUSAgNC's reduced with HH: (a) UV-absorption (b) Photoluminescence spectra.
[0047] FIG. 12 shows Fluorescence Microscopy of Nano aggregates of MUSAgNC's reduced with HH (a) Green and (b) Red filter.
[0048] FIG. 13 shows HRTEM of Nano aggregates of MUSAgNC's reduced with HH (a) high mag. Morphology, size and shape.
[0049] FIG. 14 shows TEM of Nano aggregates of MUSAgNC's reduced with HH (b) low mag. size distribution (c) diffraction.
[0050] FIG. 15 shows mass analysis of Nano aggregates MUSAgNC's reduced with HH, (a) freshly prepared (b) after 12 months of storage.
[0051] FIG. 16 shows mass and UV analysis of Nano aggregates of MUSPtNC's reduced with HH (a) Mass spectra (b) UV-absorbance spectra.
[0052] FIG. 17 shows Fluorescence Microscopy of Nano aggregates of MUSPtNC's reduced with HH (a) green filter (b) Red filter.
[0053] FIG. 18 shows HRTEM of Nano aggregates of MUSPtNC's reduced with HH (a & b) morophology; shape and size distribution (C) diffraction.
[0054] FIG. 19 shows UV absorption and Mass analysis of Nano aggregates MUSAuNC reduced with Reduced with Sodium Borohydrate (NaBh 4 ) (a) UV-absorption spectra (b) Mass spectra.
[0055] FIG. 20 shows Fluorescence Microscopy of Nano aggregates MUSAuNC Reduced with NaBH 4 (a) UV and (b) Red filter.
[0056] FIG. 21 shows HRTEM of Aqueous Synthesis of gold nanoparticles reduced with NaBH4; (a)&(b) Morphology: size and shape.
[0057] FIG. 22 shows HRTEM of Aqueous Synthesis of nano aggregates of USMAuNC reduced with NaBH4 Morphology (a) low mag. (b) high mag.
[0058] FIG. 23 shows HRTEM of Aqueous Synthesis of nano aggregates of MUSAuNC reduced with HH Morphology (a) low mag. (b) high mag.
[0059] FIG. 24 shows mass spectra of Aqueous Synthesis of nano aggregates of MUSAuNC reduced with HH.
[0060] FIG. 25 shows spectroscopy of Nano aggregate of MUSAuNC's reduced with HH and capped with MUDA: (a) UV-absorbance spectra (b) Fluorescence spectra.
[0061] FIG. 26 shows TEM of Nano aggregate of MUSAuNC's reduced with HH and capped with MUDA: (a) Morphology (b) diffraction.
[0062] FIG. 27 shows TEM and PL analysis of Nano aggregate of MUSAuNC's reduced with HH and capped with MPA: (a) Morphology (b) Photoluminescence spectra.
DETAILED DESCRIPTION OF THE INVENTION
[0063] “Gold nanoparticles/crystals” as used in the specification is with reference to definitions of Zheng et al in Nanoscale, 2012, 4, 4073
[0064] “Ligands” on the surface of nanocrystals clusters/nanoparticles, sometimes also called capping groups or surfactants, etc., are certain types of organic or bio molecules which also acts as spacer for unconstrained binding of targeted biomolecule or linker for further functionalization of biomolecule/polymer etc.
[0065] The present invention describes the 10-22 nm capped globular aggregates of molecular ultra small clusters of 1-6 atoms as in FIG. 1 .
[0066] According to the object of the invention the aggregates are characterized in having UV emissions at 300-335 nm and also have visible emissions: green when excited with blue and green filter and 590-650 nm 2 nd harmonics emission.
[0067] In accordance to the objects of the current invention the gold aggregates have no plasma resonance.
[0068] Further in accordance to the objects of the current invention spherical nano aggregates (MUSAuNC) capped with MUDA are stable at pH 3-4 and having six times higher emission as compared with amine/dicarboxyacetone capped.
[0069] In the current invention the Au aggregates are biocompatible and usable for biosensing, bioimaging, biomarker, Fluorescent Marker, UV & photo therapy and drug delivery both in vivo and in vitro applications.
[0070] In the current invention the MUDA capped by ligand exchange reaction of nano aggregates (of MUSAuNC) formed by Reverse Micro Emulsion Method as detailed below:
[0071] Oil phase: The reverse emulsion consists of cyclohexane, Triton 100X as surfactant and n hexnol as co-surfactant is prepared and split into two parts, RM 1 and RM 2.
[0000] Water phase: Consists of precursor, i.e. auric chloride (A) and reducing agent-hydrazine hydrate (HH) or Citric Acid (CA) or sodium borohydrate (B).
[0072] To RM1, A precursor is added and mixed well and to RM 2 part B reducing agent is added and mixed well. This is followed by mixing parts A to B drop wise at RT (˜25 deg C) with constant stirring. These results initially in formation of discrete Au/Ag, Pt ultra small NC (crystalline nanocluster) below 1 nm and having 1-6 atoms stabilized with amine of hydrazine hydrate or dicarboxyacetone (DCA) of citric acid because of slow inter droplet exchange. By virtue of presence of n-hexanol these MUSNbNC's are further agglomerated to the water droplet size of reverse micelle and further stabilized at fringes again with amine or DCA along with oxyethylene group of triton 100X.
[0073] The optico-physico-chemical properties of Au/Ag/Pt NC's are characterized with various characterization techniques viz. UV-Absorption; Single Photon Fluorescence Spectroscopy; Photoluminescence spectroscopy, PL; Transmission Electron Microscope(TEM) and HRTEM, X-ray Photoelectron Spectrometer, Infra-red Fourier transform technique, Zeta potential and Mass Analysis.
[0074] The particles synthesized using reverse microemulsion technique and using mild reducing agent like hydrazine hydrate and citric acid results in the formation of 10-22 nm spherical nano aggregates of molecular ultra small nanocrystals of noble metals like Au, Ag and Pt. The controlled size and shape of 10-22 nm nano aggregates with intense and multicolour (UV, green and red) fluorescence has wide range of potential applications in bio imaging for both in vitro and vivo applications. The quantum efficiency of Au nano aggregates reduced with hydrazine hydrate was 0.37 and 4.92 when reduced with citric acid. The calculations are made using the comparative method using rhodoamine B as a reference and by keeping the absorbance constant.
[0000]
QE
S
=
I
S
×
QE
R
I
R
[0000] Where, QE S : Quantum efficiency of sample
I S : Intensity of sample (359.81, Au nanoaggregate reduced with HH (0.08) and 1000 Au nano aggregate reduced with CA, 0.017)
QE R : Quantum efficiency of reference (rhodamine B, 0.65)
I R : Intensity of reference (620.65 at 0.08 and 131.88 at 0.017)
[0075] The particles synthesized using reverse microemulsion technique and strong reducing agent like sodium borohydrate; though the nano aggregates are made up of molecular ultra small nanocrystals; shows good fluorescent, there was no control over size & shape and hence cannot be used in any kind of applications. On the contrary the aqueous synthesis shows better range of size distribution i.e. 1-20 nm and also the flower like particles in the range of 20-250 nm. For utilization in particular application the particles and the flowers should be separated which is difficult task. Also the particles synthesized in aqueous phase either reduced with sodium borohydrate or hydrazine hydrate are amorphous and cannot be sediment and separated by centrifugation and the un reacted precursor and reducing agent remain the part of the solution that may interfere and cause some kind of toxicity in case of bio applications. The 1-5 nm by product of aqueous synthesis using the hydrazine hydrate as a reducing agent cannot be used in vivo applications as in long term usage 5 nm particles may accumulate in liver which can be a reason for toxicity and therefore they cannot be used for vivo applications and drug delivery. As they are not able to separate out from the reaction solution containing un-reacted precursor and reducing agent make them further unusable for drug delivery.
[0076] The MUDA capped nano aggregates of MUSAuNC's shows the stability in acidic pH. 3.5 and the fluorescence intensity was increased by six times. The MUDA capped nano aggregates of MUSAuNC's can be easily replaced with the toxic and high cost bi-functional PEG. The nano aggregates synthesized with reverse microemulsion techniques and decorated with amine/carboxyl group and also the MUDA capped by ligand exchange reaction has the potential applications as a fluorescent marker. Fluorescent biochip, various bioimaging techniques both in vivo & vitro applications, biomedical applications like drug delivery, therapy, UV & photo therapy and also simultaneously can also be used for EM labelling.
[0077] The particles are tuned to emit green and red emission by varying the capping agent. Nano rod show much higher toxicity as compared to the spherical particles. This synthesis route renders the fabrication of nano aggregates of MUSNbNC's with multiple emissions UV, red and green just by using the various excitation filters irrespective of the capping agent and being spherical and in the range of 10-22 nm they are biocompatible and flush out of body and easy cellular uptake due to low friction.
[0078] The particles are extracted and can be stored in powder form and therefore can be utilized in many electronics applications also.
[0079] Following examples are given by way of illustration therefore should not be construed to limit the scope of the invention.
EXAMPLES
Example 1
Synthesis of Spherical Nano Aggregates of Molecular Ultra Small Gold Nano Clusters (MUSNC's) Using Hydrazine Hydrate (HH) as a Mild Reducing Agent and Reverse Microemulsion Technique
[0080] Cyclohexane (C 6 H 12 ) and non ionic surfactant Triton 100-X (C 14 H 22 O(C 2 H 4 O) n (n=9-10) in 52:22 wt. % were mixed in a RB flask while continuous stirring at room temperature (25° C.) for 12 hrs and n-Hexanol (C 6 H 14 O) in 11 wt % was added into it and further stirred for 12 hrs to obtained oil phase. The oil phase was divided in two flasks. In flask-1 aqueous solution of 0.056 M of Gold Chloride was added into oil phase while stirring continuously for 12 hrs and in flask-2 (0.32 M) of Hydrazine Hydrate solution was added into oil phase while stirring continuously for 12 hrs. After that in flask 2, the solution of flask 1 is added drop by drop and stirred continuously for 10 days. The complete reaction is carried out at room temperature (˜25° C.).
[0000] Preparation of reverse micro emulsion (RM):- unit weight % 1. Cyclohexane- 52 gm } Stirring continuously on 2. Triton-100x 22 gm magnetic stirrer 3. n-Hexanol 11 gm overnight, 12 Hrs Total: 85 gm (85 Weight %)
RM Divided Equally into Two
[0000]
Preparation of Aqueous Phase:
[0081] Total 15 ml (volume %), 0.056 M of Auric Chloride prepared freshly
1. Aqueous phase 1: In 7.5 ml of distilled water 0.056 M of Auric Chloride is dissolved 2. Aqueous phase 2: In 7.5 ml of distilled water 3.2 M of Hydrazine Hydrate is dissolved
[0000]
In RM
7.5 ml of 0.056M of
While stirring continuously on
Part 1:
aqueous solution of Auric
{close oversize brace}
magnetic stirrer overnight or
Chloride is added
for minimum of 12 hours
In RM
7.5 ml 0.32M of aqueous
While stirring continuously
Part 2:
solution of Hydrazine
{close oversize brace}
on magnetic stirrer overnight
Hydrate is added
for minimum of 12 hours
[0084] After 12 hours, in RM Part 2 (Solution of Hydrazine Hydrate) and in RM Part 1 (solution of Auric Chloride) is added drop by drop and allowed to react for minimum of 10-15 days.
[0085] Extraction of Nano Aggregates of USMAuNC's:
[0086] The reaction solution containing nanoparticles is transferred in microcentrifuge tube (1.5 ml) and Centrifuge it at 5000-6000 RPM for 15 min. The supernatant is decanted and re-dissolve the precipitate in Distilled water. The particles are allowed to re-dispersed using cyclomixer (90 sec) and then with sonicator for 30 min till the complete dispersion of pellet; then again centrifuge it for 15 min's to settle down the particles and the pellet is dissolved in ethyl alcohol and the particles are again re-dispersed using cyclomixer and sonicator. The cycle is repeated twice again to remove the oil phase and surfactant completely. The Au nano aggregates are finally transferred in distilled water.
Characterization Details
[0087] UV Absorption:
[0088] The UV-visible spectra were acquired and recorded using Varian Make ‘Carry WinUV’. The grating bandwidth was of 5 nm and xenon lamp used as a light source. The slit width was of 5 nm and water dispersed nano aggregates of Au NC's was scan for 200-800 nm range. The absorption peak of as synthesized Au nano cluster aggregates were observed at 223 and 278 nm as in FIG. 2 ( a ). The 520 nm surface plasmon peak was absent.
[0089] Fluorescence Spectroscopy:
[0090] The fluorescence spectroscopy was carried out using the Varian make PL and “ISS” make Photon Counting Steady State Fluorescence Spectrophotometer; with 300 W Xe lamp. Both excitation and emission slit width was kept at 1 nm. The samples were excited from 200 to 450 nm, at 230 nm excitation the peak maxima was observed at 305 nm and 591 nm as in FIG. 2 ( b ).
[0091] Fluorescence Microscopy:
[0092] To visualize the fluorescence in optical microscope the samples were prepared by making the thick film on the glass slide and air dried. The fluorescence was observed under Meiji Techno make MT6000 optical fluorescence microscope using UV, green and red filter as in FIG. 3 .
[0093] Morphological Study:
[0094] The morphological features and size distribution of as synthesized Au NC's are measured with Carl Zeiss Make LIBRA 120, at 120 kV and at HRTEM 300 kV accelerating voltage. The samples were prepared by drop casting the water dispersed sonicated solution of particles onto the carbon coated copper grid. After air drying the samples are analyzed under TEM/HRTEM. The study shows the uniform, spherical, average size of 10-22 nm; more precisely 12-17 nm and narrow size distribution. The electron diffraction pattern (ED) shows the crystalline sharp rings as in FIGS. 4 & 5 .
[0095] Mass Spectroscopy:
[0096] The MALDI samples were prepared by using DHB (2, 5 hydroxy benzoic acid) in 50% ACN and 0.1% TFA as a matrix. The mass analysis is carried out with AB Sciex Make Voyager-DE-STR MALDI-TOF using linear positive mode and ionization of Au crystals are carried out with 337 nm nitrogen laser. The mass spectra were accumulated for the 50-100 shots for each spectrum at 20 Kv. The MALDI Analysis shows 1-6 Au Atoms on which the various species of amine group like NH, NH2, and NH3 are adsorbed. The MALDI data is a representation of the polymer like structure consisting of ultra small clusters surrounded by the various species of amine group as in FIG. 6( a ); there is very little change in the peaks of 6 months stored sample FIG. 6( b ). The assignments of mass analysis peaks as in FIG. 6 ( a ) are given below:
[0000]
TABLE 1
Nano aggregate of MUSAuNC's reduced with HH; peak assignments of
MALDI Analysis, FIG. 6 (a)
Peak
S. No.
Positions
Assignments
1.
197.90
Au 1
2.
459.48
Au 2 —(NH 2 ) 4
3.
494.75
Au 2 —(NH2) 2 —(NH 3 ) 4
4.
536.40
Au 2 —(NH) 3 —(NH 2 ) 6
5.
582.77
Au 2 —(NH 2 ) 11
6.
714.61
Au 3 —(NH)6—(NH 2 ) 2
7.
732.17
Au 3 —(NH) 16
8.
888.23
Au 4 —(NH2) 3 —(NH 3 ) 3
9.
976.25
Au 4 —(NH) 5 —(NH 2 ) 7
10.
1066.50
Au 5 —(NH2) 5
11.
1156.47
Au 5 —(NH) 6 —(NH 2 ) 5
[0097] Fourier Transform Infrared Analysis, FTIR:
[0098] FTIR spectra in the region of 4000 to 600 cm −1 were recorded with PerkinElmer Make Spectrum GX FTIR. One drop of suspended AuNC's in alcohol solution are dispersed and put onto the NACL crystal window and the peak positions of spectra were recorded and are their respective assignments are summarized in table 2, FIG. 7( a ).
[0099] Far IR:
[0100] The Far IR (ATR) analysis is carried out on Thermo-Nicolet make FTIR, 870 nexus using polyethylene detector. The most peaks are observed between 55-177 cm −1 which is related to the ultra small gold crystals: Au—Au vibrations and the attach carbon (Janet Petroski, Mei Chou, Carol Creutz; J. of Organometallic chemistry 2009, 694, 1138-1143); 7(b)
[0000]
TABLE 2
Assignments of FTIR peak; FIG. 7(a)
Frequency Wavenumber (cm −1 )
Assignments
879.19
O—H bend
1045.81
Cyclohexane ring vibration
1085.46
Cyclohexane ring vibration
1274.73
C—C vibrations; C—H bend
1320.52
C—O stresch
1405.95
C—H bend
1455.99
C—H bend
1653.29
NH bend/Aromatic combination band
1914.78
Aromatic combination band
2139.93
C—O; C═C
2903.18
C—H stretching
2935.27
C—H stretching asymmetric
3392.65
NH stretch
3361.63
NH stretch
[0101] X-ray Photo Spectroscopy, XPS:
[0102] A thin film is formed onto the silicon wafer, air dried and analyzed with VG Scientific Ltd., UK Make ESCA-3000 with a base pressure of 1.0×10 −9 Pa. and Mg Kα radiation as an X-ray source operated at 150 W. The XPS analysis confirms the oxidation state of gold is zero, Au 0 . The Au bands of as synthesized MAuNC's are at 83.09 and 86.85 as in FIG. 8 from 4f 7/2 and 4f 5/2 shell with a difference of 3.76 eV between the peaks, thus represents the zero valence of gold.
[0103] Zeta Potential:
[0104] By conducting the 10 runs and 5 cycles for each run; the mean electrostatic potential of as synthesized Au NC's is −31.8 which back up the good stability
Example 2
Synthesis of Gold Nano Aggregates of MUSNC's Using Citric Acid (CA) as a Mild Reducing Agent and Reverse Microemulsion Technique
[0105] The synthesis procedure is same as mentioned in example 1, except in aqueous phase 0.32 M Citric Acid was used instead of 0.32 M Hydrazine Hydrate.
[0106] UV Absorption:
[0107] The optical properties are similar as observed in example 1. The absorption peak of nano aggregates was observed at 223 and 277 nm as in FIG. 9 ( a ); the surface plasmon peak was absent.
[0108] Photoluminescence Spectroscopy:
[0109] The fluorescence spectroscopy is carried out using the Varian make PL. The excitation slit was kept at 2.5 nm and emission slit width was kept at 5 nm. The samples were excited from 200 to 450 nm, at 250 nm excitation the peak maxima was observed at 307 nm and 605 nm with an shift of 2 nm and 6 nm respectively as in FIG. 9 ( b )
[0110] The fluorescence was observed under Carl Zeiss BioAFM optical fluorescence microscope using Blue filter as in FIG. 10( b ).
[0111] Morphological Study:
[0112] The morphological features and size distribution of gold nano aggregates of USMAuNC's are observed and measured under HRTEM; the size, shape and distribution are similar as observed in example 1; i.e. spherical 10-22 nm uniformly dispersed as in FIG. 10( a ).
Example 3
Synthesis of Silver Nano-Aggregates of MUSNC Reduced with Mild Reducing Agent Hydrazine Hydrate and Reverse Microemulsion Technique
[0113] The synthesis procedure is same as mentioned in Example 1, except in aqueous phase 0.056 M of precursor silver nitrate is used instead of auric chloride.
[0000] The optical properties are similar as observed in Example 1 and 2, the absorption peaks were observed at near 222 nm and 277 nm, as in FIG. 11 ( a ) with same instrument parameters as mentioned in Example 1 and fluorescence emission is at 302 nm and 600 nm as in FIG. 11 ( b ) analyzed with varian make PL with same instrumentation parameters as mentioned in Example 2. It shows the green and red emission using green and red filter under optical fluorescence microscope as in FIG. 12 .
[0114] The TEM and HRTEM analysis shows 10-22 nm spherical crystalline clusters with narrow size distribution of nano aggregates, as in FIGS. 13 & 14 .
[0115] The mass analysis shows the clusters of 1-10 atoms decorated with amine group, as in FIG. 15 . It shows slightly more atoms as compared in case of Au atoms. In case of Au atoms are restricted to 1-5 or maximum of 7 atoms where as in case of Ag nano particles the clusters are slightly bigger i.e. 1-10 atoms maximum of 12-14 atoms decorated with NH/NH 2 /NH 3 molecules on the surface. The increase in number of atoms in case of Silver nano crystals might be due to small mass or atomic radii as compared with gold. There was not much change in the spectra of freshly prepared and after storing the particles in emulsion for 12 months ( FIG. 15 ).
Example 4
Synthesis of Platinum Nano-Aggregates of MUSNC Reduced with Mild Reducing Agent Hydrazine Hydrate and Reverse Microemulsion Technique
[0116] The synthesis procedure is same as mentioned in Example 1, except in aqueous phase 0.056 M of precursor platinum chloride was used.
[0117] The optical and morphological features and mass analysis results are similar as observed in example 1, 2 and 3 as indicated in FIGS. 16 , 17 and 18 .
Example 5
Synthesis of Gold Nano-Aggregates of MUSNC Reduced with Strong Reducing Agent Sodium Borohydrate (NaBH4) and Reverse Microemulsion Technique
[0118] The synthesis procedure, instrumentation and sample preparation techniques was same as mentioned in Example 1, except in aqueous phase 0.32 M of sodium borohydrate was used as a reducing agent instead of hydrazine hydrate.
[0119] The UV analysis results were similar as observed in Example 1-4. The absorption peaks of nano aggregates were observed at 223 and 277 nm as in FIG. 19( a ); the surface plasmon peak was absent. The fluorescence was observed under Miji Fluorescence optical Microscope using UV and Red filter as in FIG. 20 . The HRTEM analysis shows that there is no control on size and shape. The particles are spherical, triangles and hexagonal etc and the size range is 1-250 nm, very wide range of size distribution; FIG. 21 . The mass analysis shows very similar results observed in Examples 1-4; as in FIG. 19 ( b ).
Example 6
Aqueous Synthesis of Gold Nano Nanoparticles Reduced with Strong Reducing Agent Sodium Borohydrate (NaBH4) while Continuous Stirring
[0120] In RB flask-1, 0.056 M of Auric Chloride is dissolved in 10 ml of Millipore water and stirred for 12 hrs on magnetic stirrer. In RB flask-2 (0.32 M) of sodium borohydrate is dissolved in 10 ml of distilled water and stirred for 12 hrs. Next day 0.056 M of aqueous solution of RB flask-1, Auric Chloride is added drop by drop into the in RB Flask-2 containing 0.32 M of aqueous solution of sodium borohydrate. It forms the black precipitate, the reaction is carried out for 3-5 days and particles are characterized using the same instrumentation and sample preparation methods as described in Example 1.
[0121] The particles do not show fluorescence and the HRTEM analysis ( FIG. 22 ) shows particles in the range of 1-20 nm and flower like structure in the range of 20-250 nm. The particles can not be extracted by centrifugation and the unreacted precursor and reducing agent remained the part of colloidal solutions.
Example 7
Aqueous Synthesis of Gold Nano Nanoparticles Reduced with Mild Reducing Agent Hydrazine Hydrate (HH) while Continuous Stirring
[0122] The synthesis, instrumentation and sample preparation methodology was same as mentioned in example 6, except 0.32 M Hydrazine Hydrate was used instead of sodium borohydrate. It forms the black precipitate. The reaction was carried out till the dissolution of pellete.
[0123] HRTEM analysis shows the narrow size distribution in the range of 1-5 nm and the particles are amorphous as in FIG. 23 . The mass analysis shows the capping of amine groups ( FIG. 24 ). As mentioned in Example 6, here also the particles can not be extracted by centrifugation and the unreacted precursor and reducing agent remained the part of colloidal solutions.
Example 8
Capping of MUSAuNC's by Ligand Exchange with Mercaptoundeconic Acid (MUDA)
[0124] MUSAuNC's was synthesized in example 1. (250 mg of) MUA was first dissolved in 5 ml water and 10 ml ethyl alcohol for 5 hour while continuous stirring on magnetic stirrer. This forms milky white solution. After 5 hours 10 ml of chloroform was added and stirred for 12 hrs then ˜5 mg of MUSAuNC's dispersed in 5 ml of distilled water was added and allowed to react for 20 days. The exchange of ligand MUDA was checked with the help of zeta potential when complete negative charge on the MUSAuNC's was replaced by +ve charge of SH group (as in table 3). pH of synthesized with Hydrazine hydrate was 3 and pH after capping with MUDA was 3.5.
[0125] There was reduction in absorption intensity but no shift in absorbance wavelength as in FIG. 25( a ), and the fluorescence intensity was increased six times as compared with FIG. 2 ( b ) which was near 45000 to 300000 as in FIG. 25( b ). There was no change in morphology as observed in FIG. 26 .
[0000]
TABLE 3
Zeta potential of MUDA capped MUSAuNC's
Zeta Potential (mV)
Zeta Potential (mV)
MUDA dissolved
MUDA dissolved in 1:1:1
in 50% Alcohol;
water:Alcohol:chloroform;
S. NO.
10 days reaction
25 days reaction
1.
−12.47
7.82
2.
−15.76
8.27
3.
−24.91
−3.78
4.
−25.72
2.35
5.
−22.92
6.63
Mean
−20.35
4.25
Example 9
Capping of MUSAuNC's by Legand Exchange with Mercaptopropionic Acid (MPA)
[0126] MPA was dissolved in 5 ml of 50% of alcohol while continuously stirring, then in 5 ml water containing nano aggregates of MUSAuNC's was synthesized in example 1 was added and allowed to react for 4-8 days till the surface is completely replaced by MPA. The results were similar as observed in example 1. The mean Zeta potential of MPA capped MUSAuNC's was 14.47 mV ( FIG. 27 )
[0000]
TABLE 4
Comparative table
Fluorescence
Fluorescence
Fluorescence
emission
Nanoparticle/
emission
emission
Red and
Surface
Reference
nanocluster size
Capping
UV
Green
near IR
plasmon
Present
10-22 nm capped
Amine
300-330
Using blue
590-620
Absent
invention
Spherical Au nano
Carboxyl
and green
aggregates
Au nano
filter
10-22 nm capped
aggregate
300-330
Using blue
590-620
Absent
Spherical Ag nano
are
and green
aggregates
further
filter
10-22 nm capped
capped
300-330
Using blue
590-620
Absent
Spherical Pt nano
with
and green
aggregates
MPA &
filter
MUDA
Beatriz
Clusters of Au 2 to
PVP
315-350 nm
520 nm
Not
Absent
Santiago
Au 11
shown
Gonzalez
Size below 1 nm
et al; Nano
let. 2010,
10, 4217-4221
Walter H
Au 8
PAMAM
Blue
absent
absent
absent
Chang etal;
emission
J. of Med.
AuNP-THPC
Replace
absent
Green
absent
Not
And
with
emission
shown
Bioloical
MUA
Engg.,
~3.4 nm
BSA
absent
absent
Red
absent
2009, 29
Au 25
Emission
(6), 276-283
5.55 nm AuNP
absent
absent
absent
absent
520-530 nm
and
C. A. J Lin
et al;
ESBME-
Peter
Thalappail
Au 25 SG 18
absent
absent
absent
Near IR
absent
pradeep
etal;
Chemical
Eur. J.;
2009, 15,
10110-10120
P. K. Jain
10 nm Au
absent
absent
absent
absent
520
et al, ACS,
nanospheres
—
—
—
Accounts
10 nm Ag
absent
absent
absent
absent
390
of chem. 1
Nanosphere
Res. Dec.
2008, 41
(12), 1578-1586
ADVANTAGES OF THE INVENTION
[0000]
Low toxicity and more biocompatible
Easy synthesis as compared to bifunctional PEGNP′c where there is requirement of vacuum environment and reaction is quite volatile requiring expertise for synthesis
Preparation is cost effective.
MUDA capped AuNC's do not require fluorescence markers and work at low pH hence can be used for bio-sensing/bio imaging and drug delivery simultaneously.
Process is environmental friendly | 4y
|
BACKGROUND
[0001] A fuel cell is an energy conversion device that generates electricity and heat by electrochemically combining a gaseous fuel, such as hydrogen, carbon monoxide, or a hydrocarbon, and an oxidant, such as air or oxygen, across an ion-conducting electrolyte. The fuel cell converts chemical energy into electrical energy. A fuel cell generally consists of two electrodes positioned on opposite sides of an electrolyte. The oxidant passes over the oxygen electrode (cathode) while the fuel passes over the fuel electrode (anode), generating electricity, water, and heat. There are several types of fuel cells, including proton exchange membrane (PEM) fuel cells and solid oxide fuel cells (SOFC).
[0002] In a typical SOFC, a fuel flows to the anode where it is oxidized by oxygen ions from the electrolyte, producing electrons that are released to the external circuit, and mostly water and carbon dioxide are removed in the fuel flow stream. At the cathode, the oxidant accepts electrons from the external circuit to form oxygen ions. The oxygen ions migrate across the electrolyte to the anode. The flow of electrons through the external circuit provides for consumable or storable electricity. However, each individual electrochemical cell generates a relatively small voltage. Higher voltages are attained by electrically connecting a plurality of electrochemical cells in series to form a stack.
[0003] The fuel cell stack also includes conduits or manifolds to allow passage of the fuel and oxidant into and byproducts, as well as excess fuel and oxidant, out of the stack. Generally, oxidant is fed to the structure from a manifold located on one side of the stack, while fuel is provided from a manifold located on an adjacent side of the stack. The fuel and oxidant are generally pumped through the manifolds and introduced to a flow field disposed adjacent to the appropriate electrode. The flow fields that direct the fuel and oxidant to the respective electrodes, typically create oxidant and fuel flows across the electrodes that are perpendicular to one another.
[0004] The long term successful operation of a fuel cell depends primarily on maintaining structural and chemical stability of fuel cell components during steady state conditions, as well as transient operating conditions such as cold startups and emergency shut downs. The support systems are required to store and control the fuel, compress and control the oxidant and provide thermal energy management. A fuel cell can be used in conjunction with a reformer that converts a fuel to hydrogen and carbon monoxide (the reformate) usable by the fuel cell. Three types of reformer technologies are typically employed (steam reformers, dry reformers, and partial oxidation reformers) to convert hydrocarbon fuel (methane, propane, natural gas, gasoline, etc) to hydrogen using water, carbon dioxide, and oxygen, respectfully, with byproducts including carbon dioxide, carbon monoxide, and water, accordingly.
[0005] The fuel cell system is dependent upon the reformate created. Steam processing of fuels is efficient since it produces a greater amount of fuel per unit of pre-reformed fuel than the partial oxidation reformer. However, storage of water for supply to the fuel cell system requires a large amount of space, additional weight, and time-consuming maintenance.
SUMMARY
[0006] The drawbacks and disadvantages of the prior art are overcome by water recovery for a fuel cell system.
[0007] A fuel cell system is disclosed. A fuel cell stack is in fluid communication with a reformer, which is in fluid communication with an air conditioning system.
[0008] A method of making a fuel cell system is also disclosed. The method comprises disposing a reformer in fluid communication with a fuel cell stack and disposing an air conditioning system in fluid communication with the reformer.
[0009] A method of using a fuel cell system is also disclosed. The condensate from an air conditioning system is directed to a reformer. The reformer is operated to produce a reformate and the reformate is utilized in a fuel cell stack to produce electricity.
[0010] A fuel cell system is disclosed. The fuel cell system comprises a means for producing electricity from a reformate, a means for producing the reformate from a condensate, and a means for producing the condensate from air.
[0011] A fuel cell system is disclosed. The fuel cell system comprises a proton exchange membrane fuel cell stack and an air conditioning system in fluid communication with the proton exchange membrane fuel cell stack.
[0012] A method of using a fuel cell system is disclosed. The method comprises producing a condensate in an air conditioning system and hydrating a proton exchange membrane fuel cell with at least a portion of the condensate.
[0013] The above described and other features are exemplified by the following figures and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Referring now to the figures, wherein like elements are numbered alike in the several figures:
[0015] [0015]FIG. 1 is a schematic of an exemplary fuel cell system;
[0016] [0016]FIG. 2 is a schematic of an exemplary fuel cell system incorporating recovery of water from the air conditioning system through a reservoir; and
[0017] [0017]FIG. 3 is a schematic of an exemplary fuel cell system incorporating recovery of water from the air conditioning system.
DETAILED DESCRIPTION
[0018] A fuel cell system may be utilized with an engine to operate a vehicle. The power created from the engine and the fuel cell can propel a vehicle, as well as providing electricity and heat for the auxiliary systems. The created electricity can be provided to an air conditioning system for climate control in the vehicle. The air conditioning system, in turn, creates water as a byproduct, which can be recovered for use in the reformer of the fuel cell system.
[0019] Generally, a fuel cell system may comprise at least one fuel cell (preferably, SOFC or PEM), an engine, one or more heat exchangers, and optionally, one or more compressors, an exhaust turbine, a catalytic converter, preheating device, plasmatron, electrical source (e.g., battery, capacitor, motor/generator, turbine, and the like, as well as combinations comprising at least one of the foregoing electrical sources), and conventional connections, wiring, control valves, and a multiplicity of electrical loads, including, but not limited to, lights, resistive heaters, blowers, air conditioning compressors, starter motors, traction motors, computer systems, radio/stereo systems, and a multiplicity of sensors and actuators, and the like, as well as conventional components.
[0020] The recovery of water for a fuel cell system described herein utilizes a SOFC system, although any fuel cell system, including SOFC systems and PEM fuel cell systems, can be used. Referring now to FIG. 1, a fuel cell system 10 is schematically depicted. The fuel cell system 10 comprises a fuel cell stack 24 , preferably contained within an enclosure 20 for thermal management (also referred to as a “hot box”). The fuel cell stack 24 , which may also comprise a plurality of modular fuel cell stacks, is generally coupled to a fuel (or reformate) inlet 34 , an exterior air (or oxidant) supply inlet 32 , and a heated air (or oxidant) supply inlet 33 .
[0021] To facilitate the reaction in the fuel cell, a direct supply of fuel, such as hydrogen, carbon monoxide, or methane, is preferred. However, concentrated supplies of these fuels are generally expensive and difficult to supply. Therefore, the specific fuel can be supplied by processing a more complex source of the fuel. The fuel utilized in the system is typically chosen based upon the application, expense, availability, and environmental issues relating to the fuel.
[0022] Possible sources of fuel include conventional fuels such as hydrocarbon fuels, including, but not limited to, conventional liquid fuels, such as gasoline, diesel, ethanol, methanol, kerosene, and others; conventional gaseous fuels, such as natural gas, propane, butane, and others; and alternative fuels, such as hydrogen, biofuels, dimethyl ether, and others; and combinations comprising at least one of the foregoing fuels. The preferred fuel is typically based upon the power density of the engine, with lighter fuels, i.e. those which can be more readily vaporized and/or conventional fuels which are readily available to consumers, generally preferred.
[0023] Located within the fuel cell system enclosure 20 , is the reformer system 22 that comprises a main reformer, and optionally, a micro-reformer. The reformer 22 is provided with a fuel through a fuel inlet 30 , an exterior air (or oxidant) inlet 32 , and a water supply inlet 35 . The reformer system 22 can be thermally isolated from the fuel cell stack 24 (i.e., a segmented enclosure, isolated enclosure, or the like). The processing or reforming of hydrocarbon fuels, such as gasoline, is completed to provide an immediate fuel source for rapid start up of the fuel cell as well as protecting the fuel cell by removing impurities. Fuel reforming can be used to convert a hydrocarbon (such as gasoline) or an oxygenated fuel (such as methanol) into hydrogen (H 2 ) and byproducts (e.g., carbon monoxide (CO), carbon dioxide (CO 2 ), and water). Common approaches include steam reforming, partial oxidation, and dry reforming.
[0024] Steam reforming systems involve the use of a fuel and steam (H 2 O) that is reacted in heated tubes filled with catalysts to convert the hydrocarbons into principally hydrogen and carbon monoxide. An example of the steam reforming reaction is as follows:
CH 4 +H 2 O→CO+3H 2
[0025] Partial oxidation reformers are based on substoichiometric combustion to achieve the temperatures necessary to reform the hydrocarbon fuel. Decomposition of the fuel to primarily hydrogen and carbon monoxide occurs through thermal reactions at high temperatures of about 700° C. to about 1,000° C. The heat required to drive the reaction is typically supplied by burning a portion of the fuel. Catalysts have been used with partial oxidation systems (catalytic partial oxidation) to promote conversion of various sulfur-free fuels, such as ethanol, into synthesis gas. The use of a catalyst can result in acceleration of the reforming reactions and can provide this effect at lower reaction temperatures than those that would otherwise be required in the absence of a catalyst. An example of the partial oxidation reforming reaction is as follows:
CH 4 +½O 2 →CO+2H 2
[0026] Dry reforming involves the creation of hydrogen and carbon monoxide in the absence of water, for example using carbon dioxide. An example of the dry reforming reaction is depicted in the following reaction:
CH 4 +CO 2 →2CO+2H 2
[0027] The reformer system 22 , preferably utilizing a steam reformer, creates a reformate 34 for use by the fuel cell system 24 . The fuel cell system 24 uses this reformate 34 to create electrical energy 44 for harnessing and waste byproducts; thermal energy, spent/unreacted fuel 36 , and spent air 42 . Thermal energy from the flow of spent/unreacted fuel 36 can optionally be recovered in a waste energy recovery system 26 , which can recycle the flow of fuel 38 and waste heat combined with oxidant from an exterior air (or oxidant) inlet 32 , to the fuel reformer 22 and can also discharge a flow of reaction products (e.g., water and carbon dioxide) 40 from the system. Alternatively, some or all of the spent/unreacted fuel 36 may be introduced to an engine (not shown) or a turbine (not shown) for energy recovery. Additionally, unreacted oxygen and other air constituents 42 are discharged from the fuel cell stack 24 . Ultimately, electrical energy 44 is harnessed from the fuel cell for use by a motor vehicle (not shown) or other appropriate energy sink.
[0028] As indicated above, the preferred reformer system includes the use of a steam reformer. A steam reformer is more efficient since it produces a greater amount of fuel per unit of pre-reformed fuel than the partial oxidation reformer. However, a steam reformer requires a source of water (i.e., steam) to produce the necessary reactions in creating a reformate. Conventional systems require that canisters of water be stored near the reformer. This requires much space and maintenance to ensure the proper amount of water is available to the system.
[0029] To avoid the requirements of space and maintenance, a possible source of water that can be harnessed for use by the reformer is from the air conditioning system. As part of the process of removing thermal energy from the air, the air conditioning system condenses water vapor from the air, collects it, and discharges the water from the air conditioning system. As illustrated in FIG. 2, a flow of condensate 52 from the air conditioning system 50 can be directed to the reformer system 22 . This condensate can constitute all, or at least a portion of the reformer's water supply. Preferably, condensate 52 from the air conditioning system 50 is directed to a storage vessel or reservoir 54 for storage until the flow of condensate 56 is needed by the reformer system 22 . The reservoir 54 can include a device for purifying the condensate to at least partially, or completely, remove unnecessary components to improve its quality and purity. Such purification devices can include filters, deionizers, and distillers and combinations comprising at least one of the foregoing devices. In the alternative, the flow of condensate 52 can be directly connected to the reformer system 22 , as illustrated in FIG. 3.
[0030] The air conditioning system circulates a flow of warm moist air from outside the system with a blower. Moisture from the air is condensed on an evaporator in the air conditioning system creating water as a byproduct. This water can be directed to the fuel cell system reformer (See FIGS. 2 and 3). Although traditionally the primary function of the air conditioning system is to provide cabin comfort, there may be an opportunity to enhance the production of condensate from the air conditioning system for use by the reformer. In order to provide an ample water supply for the reformer, the mass flow rate of warm moist air from outside flowing through the evaporator can be biased (either higher or lower) thereby accommodating both the cabin comfort and reformer condensate requirements. This can be accomplished by adjusting the speed of the blower in the air conditioning system and/or varying the air distribution and temperature control valves. Additionally, in order to optimize the production of condensate from the air conditioning system, sensors and electronic controls could be utilized that would determine a reservoir water level (indicative of the desired condensate level), an ambient air temperature and humidity level (indicative of the potential for condensate generation), and a cabin temperature and humidity level (indicative of the level of cabin comfort) that when interpreted, could allow for the air control biases described above. This would, in turn, produce more or less condensate as the cabin comfort system allows, the reformer system needs, and the ambient air allows. In other words, the amount of condensate produced can be controlled to enable the maintenance of a sufficient water reservoir for use in the reformer.
[0031] In a case where a sufficient supply of water is not provided by the air conditioning system and/or during system start-up, the reformer system can be operated utilizing a partial oxidation reaction process. Employment of the partial oxidation process eliminates the need for water in the production of reformate, while producing heat capable of bringing the fuel cell up to the desired temperature. Alternatively, some or all of the water produced in the fuel cell can be directed for use in the reformer. Thereby, supplying the reformer with water until the flow of water from the air conditioning system is restored.
[0032] During operation, the air conditioning system produces a condensate that is captured and directed to the reformer. The reformer uses this supply of water in reforming various types of fuel to produce a reformate, i.e., fuel for a fuel cell. The reformate is then utilized by the fuel cell stack in its production of electricity.
[0033] In an alternative process, the reformer can be by-passed, with at least a portion of all of the condensate from the air conditioning system utilized in a PEM fuel cell system, e.g., as the water management. Water is utilized by a PEM fuel cell for hydrating the anode and cathode input gases during the operation of the PEM fuel cell.
[0034] The use of water from the air conditioning system provides a more efficient source of water without requiring the owner to constantly maintain the levels of water required for the fuel cell system. Likewise, by supplying water from the air conditioning system system, the requirement of storage space for water canisters is relieved.
[0035] While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration only, and such illustrations and embodiments as have been disclosed herein are not to be construed as limiting to the claims. | 4y
|
This is a continuation-in-part, of application Ser. No. 490,997, filed May 3, 1983 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of reinforced glass structures in general, and in particular, to laminated safety glass reinforced with ionomer resin films and/or polycarbonates. Laminates of glass, ionomer resin and metal are also contemplated in the invention.
2. Description of Prior Art
Safety glass can be reinforced by lamination with an inner layer of polycarbonate. The resulting lamination, however, is impractical for two principal reasons. One reason is insufficient bond strength when the polycarbonate is bonded directly to the glass. A second, and even more important reason stems from polycarbonate and glass having different co-efficients of thermal expansion. Safety glass laminates may be bonding polycarbonate directly to glass will crack and craze on cooling from the temperature necessary to bond the two together, due to the different thermal expansion co-efficients of the components.
Initial attempts to solve these problems involved interposing additional interlayers of polyvinyl butyral between the polycarbonate and the glass. Adhesion between the polycarbonate and the glass proved insufficient unless a plasticizer was also used. However, when a plasticizer was used, the plasticizer often caused the polycarbonate to develop stress cracks, and accordingly, to have low light transmission properties.
The initial problems appear to have been solved in the laminated safety glass described in U.S. Pat. No. 3,888,032, which has achieved wide commercial success. The laminate comprises polycarbonate reinforced glass wherein the polycarbonate and glass are bonded to one another by an interlayer of polyurethane. Polyurethane provides sufficient adhesion to glass and to the polycarbonate, and no stress cracking or cloudiness develops in the product.
Despite the commercial success of the polyurethane laminated product, there has been a continuing effort to develop less expensive products, particularly as polyurethane is an expensive component. This invention provides new glass laminates, with and without layers of polycarbonates, and other reinforcing transparent plastics, which are considerably less expensive than the polyurethane laminates, yet which at the same time are every bit as satisfactory, if not more so, with regard to adhesion, strength and clarity. Laminates according to this invention comprise at least one layer of glass laminated with an iomoner resin film.
In the specification and claims the terms "ionomer" or "ionomer resin" mean an extrudable resin comprising ionically crosslinked ethylene-methacrylic acid copolymers; and more particularly, sodium or zinc crosslinked ethylene-methacrylic acid copolymers. Properties which distinguish ionomer resins from other polyolefin heat-seal polymers are high clarity, melt strength, solid-state toughness and resistance to oil/fat permeation. Ionomer resins are generally available as either a sodium or a zinc ionomer, and are available in a wide variety of grades. Amine ionomers are also produced. Although all grades of ionomer resins generally exhibit the properties noted above when compared to other heat-sealed polymers, sodium ionomers are known for exceptional toughness and resistance to fats and oils, while zinc ionomers exhibit outstanding adhesion to unprimed foil and process excellent chemical resistance. Sodium ionomers have proved to provide the best clarity, the zinc ionomers proving hazy at times.
Various grades of ionomer resins are available for extrusion coating and film extrusion. It is also known that ionomer resins can be co-extruded with other plastic resins and exhibit adhesion to other polyolefins, nylon resins and coextrudable adhesive resins often used as bonding layers in multi-ply coextruded structures. A very wide variety of ionomer resins are manufactured by E. I. DuPont de Nemours and Company under the registered trademark "SURLYN".
Ionomer resins have been suggested for use primarily in the area of packaging, for foods, liquids and pharmaceuticals, as well as certain industrial applications including lightweight sails, bonded cable sheath, roof underlayment and flame retardant products. In most applications, ionomer resins ae offered as superior substitute for polyethylene. In none of the literatur or prior art is there any suggestion that ionomer resins should or could be used for reinforcing glass layers or for bonding layers of glass to polycarbonate or other plastic layers, in order to form a laminated safety glass. Moreover, there is no suggesion in the literature or prior art indicating the ionomer resins could or should be substituted generally for polyurethanes.
Layers of ionomer resins can be formed by casting or extrusion, the latter being preferred. One formed there are no significant differences between cast and extruded layers. When the ionomer resin layers are sufficiently thick, polycarbonate layers can be eliminated altogether.
Ionomer resins have several advantages over polyurethane. Polyurethane is difficult to manufacture and hard to fabricate. It is frequently not clear enough for use in windshields and the like. By contrast, ionomer resin films can be easily extruded to desired thicknesses, and at about one-half the material cost of polyurethane. Ionomer resins have demonstrated better adhesion characteristics to polycarbonates, as well as better resistance to lower temperatures. In preferred embodiments, the surface to which the ionomer resin is adhered may be primed to get good adhesion, as is the case with polyurethane. Silane coupling agents are suitable primers. With regard to optical properties, ionomer resins demonstrate better clarity than polyurethane. Moreover, the ionomer resins are more hydrolytically stable to water, acids and bases, are more resistant to degradation from ultraviolet light, and overall, are less likely to weaken with time. This greatly enhances the useful life of laminates made in accord with the present invention.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a laminated article based on laminates of glass and ionomer resins, and depending upon application, laminates of glass, ionomer resin and polycarbonate or other transparent plastics as well. The laminated articles have all of the advantages and positive features of laminates of glass and polyurethane, but are significantly less expensive to produce and have other enhanced features such as increased clarity and greater useful life.
It is another object of this invention to provide a laminated article of glass, ionomer resin and polycarbonate which has good adhesion and which is transparent and resistant to breakage.
It is still another object of this invention to provide a laminated article of glass, ionomer resin and polycarbonate which has good strength properties over a wide temperature range.
These and other objects of this invention are accomplished by articles comprising a lamina of ionomer resin film laminated to a sheet of glass. The ionomer resin film is preferably an ionically crosslinked ethylene-methacrylic acid copolymer. The laminated articles may also comprise a sheet of polycarbonate laminated to the ionomer resin film opposite the glass. The laminated articles may further comprise an ionomer resin film sandwiched between two sheets of glass. The laminated articles may still further comprise a sheet of polycarbonate sandwiched between sheets of ionomer resin film, which are in turn sandwiched between sheets of glass. The laminated articles may still further comprise an ionomer resin film sandwiched between a sheet of glass and a sheet of acrylic plastic and an ionomer resin film sandwiched between a sheet of glass and a sheet of metal. The laminated articles may also comprise any number of lamina of glass sandwiched with a lamina of ionomer resin, the resultant laminate having glass as the outer lamina.
BRIEF DESCRIPTION OF THE DRAWING
The Figures illustrate cross-section views through portions of laminated articles made in accordance with this invention, wherein:
FIG. 1 is a glass/ionomer resin laminate;
FIG. 2 is a glass/ionomer resin laminate having a hard coat on the otherwise exposed surface of the ionomer resin layer;
FIG. 3 is a glass/ionomer resin/polycarbonate laminate;
FIG. 4 is a glass/ionomer resin/polycarbonate laminate having a hard coat on the otherwise exposed surface of the polycarbonate layer;
FIG. 5 is a glass/ionomer resin/glass laminate;
FIG. 6 is a glass/ionomer resin/polycarbonate/ionomer resin/glass laminate;
FIG. 7 is a glass/ionomer resin/acrylic plastic laminate;
FIG. 8 is a glass/ionomer resin/metal laminate; and
FIG. 9 is a glass/ionomer resin/glass/ionomer resin/glass/ionomer resin/glass laminate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The basic laminated safety glass article according to this invention is shown in FIG. 1. The laminate 10 comprises a sheet of glass 12 laminated to an ionomer resin layer 14. The ionomer resin layer 14 is thicker in the basic laminated article than in articles including a layer of polycarbonate or a second layer of glass.
A second embodiment of a laminated safety glass article according to this invention is shown in FIG. 2. The laminate 20 comprises a sheet of glass 22 and an ionomer resin layer 24, similar to the laminate 10 of FIG. 1. However, the embodiment of FIG. 2 is further provided with a hard coat 26 on the otherwise exposed surface of the ionomer resin film, in order to protect the ionomer resin film form scratching, abrasion and other similar damage. A "hard coat" provides abrasion resistant, optically transparent coatings which serve to protect the surface and render the laminate more resistant to scratching and the like. Useful "hard coat" compositions are described in U.S. Pat. No. 4,027,073 and U.S. patent application Ser. No. 473,790, filed Mar. 10, 1983, and assigned to the owner of this application.
A third embodiment of a laminated safety glass article according to this invention is shown in FIG. 3. The laminate 30 comprises a sheet of glass or a transparent polyester, such as Mylar 32 laminated to an ionomer resin film 34, which is in turn laminated to a polycarbonate, polyurethane or acrylic layer 36. As additional strength is provided by the layer 36, the ionomer resin layer 34 may be thinner than the ionomer resin layer 14 in the embodiment shown in FIG. 1 optionally the Mylar may be provided with a hard coating.
A fourth embodiment of a laminated safety glass article according to this invention is shown in FIG. 4. The laminate 40 is similar to that of FIG. 3, in comprising a glass sheet 42, an ionomer resin layer 44 and a polycarbonate layer 46. Although polycarbonate is used to provide additional strength to the laminate, polycarbonates are usually too soft, and therefore subject to scratches and abrasion. Accordingly, the laminate 40 is provided with a hard coat layer 48 for protecting the otherwise exposed surface of the polycarbonate layer 46.
A fifth embodiment of a laminated safety glass article according to this invention is shown in FIG. 5. The laminate 50 comprises two sheets of glass 52, 54 joined by an ionomer resin layer 56. As no soft surfaces are exposed, no hard coat layer is necessary.
A sixth embodiment of a laminated safety glass article according to this invention is shown in FIG. 6. The laminate 60 comprises first a polycarbonate layer 62 sandwiched between two ionomer resin layers 64, 66. The ionomer resin/polycarbonate/ionomer resin laminate is itself sandwiched between two glass sheets 68 and 70. As might be expected, the thicker and more complex laminate 60 shown in FIG. 6 is more expensive to produce than the laminates shown in FIGS. 1-5, but it exhibits the greatest strength and resistance to shattering and spalling.
A seventh embodiment of a laminated safety glass article according to this invention is shown in FIG. 7. The laminate 70 comprises a sheet of glass 72 and a sheet of polyurethane or acrylic plastic 76 joined by an ionomer resin film layer 74. The polyurethane or acrylic plastic layer 76 may or may not be coated with an appropriate hard coat.
An eighth embodiment of a laminated safety glass article according to this invention is shown in FIG. 8. The laminated article 80 comprises a sheet of glass 82 and a sheet of metal 86 joined by an ionomer resin film layer 84. The metal layer 86 may be any metal such as aluminum, silver, iron and copper.
A ninth embodiment of a laminated safety glass article according to this invention is shown in FIG. 9. The laminated article 90 comprises sheets of glass 92, 96, 100 and 104 sandwiched by ionomer resin film layers 94, 98 and 102.
A number of transparent laminates were prepared for a first series of tests, using a 2.5 millimeter thick sheet of float glass, a 1/8 inch sheet of polycarbonate and a 30 mil thick layer of an ionomer resin film. The ionomer resin film incorporated in the laminate is formulated by melting the ionomer resin pellets, preferably under an inert atmosphere, such as may be provided by nitrogen, at about 380° F., and extruding the molten resin through a die in accordance with procedures well known in the art. Films varying in thickness from 1 mil to 100 mils may be used in the laminates of the invention. The ionomer resin film may be rolled and stored, preferably in a bag or other container to protect it from dust, dirt or other contaminates. The ionomer resin pellets may also be melted and poured into a mold to produce cast sheets of ionomer resin for use in preparing the desired laminates.
The sheets and layers were approximately 4 inches by 5 inches in size to facilitate handling and processing. In particular, the ionomer resin film was "SURLYN" 1601, manufactured by Polymer Products Department of the DuPont Company. The melt index of "SURLYN" 1601 is 1.3 dg/min, ASTM D-1238. The ion type is sodium and the density is 0.94 g/cc. A data information sheet on "SURLYN" 1601 ionomer resin (for flexible packaging) is available under the number E-29173 (7/81). The information of this technical release, including the rheology curves, is incorporated herein by reference. SURLYN type 1707 is also a preferred sodium ionomer resin for use in this invention.
Organic amines may be combined with the ionomer resin in an amount of from about 0.5 to 7%, by weight, based on the weight of the resin. It has been found that the presence of an organic amine in the ionomer resin may serve to maintain the optical clarity of the laminates produced in the invention. The commercially available organic amines are simply combined with the ionomer resin pellets and extruded or cast as desired.
Likewise, a mixture of sodium and zinc ionomer resins may be used to prepare the ionomer resin film useful in the invention. The sodium and zinc ionomer resins may be combined in a ratio of 95:5 to 5:95.
For purposes of simplifying the test, the sandwich was constructed with one outer layer of glass, one inner layer of ionomer resin and one outer layer of polycarbonate. A three layer laminate as tested can be fully expected to perform in the same manner as a five layer lamination such as that shown in the drawing with regard to adhesion, if not overall strength. The sandwiched laminates were assembled in a vacuum bag and placed in an autoclave. The samples were heated to a temperature of from about 200° F. to about 275° F. over a 45 minute period, were held at the elevated temperature for about 15 minutes, and were then cooled to room temperature, approximately 65° F.-70° F. After cooling, the laminates were immersed in boiling water in an effort to promote premature and unwanted delamination. Throughout all of the examples herein, the same basic procedure, involving vacuum bag, autoclave, heating up, sustained heating and cooling were followed unless otherwise noted.
The tests were conducted with and without certain primers to promote adhesion between the ionomer resin and the glass and polycarbonate respectively. Primers suitable for glass, and the glass/ionomer resin interface in particular, were found to include salines, such as those produced under the registered trademarks "Z-6040" and "Z-6020" by Dow Chemical Company. Other primers suitable for the polycarbonate/ionomer resin interface in particular, were found to include organic amines, usually in a diluted solution with an inert solvent (unlikely to attack the polycarbonate, e.g. alkanes and alcohols), such as aliphatic or polyethylene amines or ethanolamines, and specifically diethylenetriamine. Other specific primers include diisocyanates (toluene diisocyanate) and polyacrylic acid (produced under the registered trademarks "ACRYLOID" and "ACRYSOL" by the Rohm and Haas Company).
EXAMPLE 1
A laminate of glass and ionomer, the glass surface to be laminated to the ionomer resin having been primed with Dow Z-6020 was formed following the procedure set forth above. The laminate did not undergo delamination in boiling water.
EXAMPLE 2
A 30 cm by 30 cm laminate comprising a 3 mm thick clear polycarbonate sheet sandwiched between two 0.7 mm thick ionomer resin films made from SURLYN 1601 which in turn are sandwiched between 2.5 mm thick sheets of chemically strengthened glass was prepared following the procedure set forth above. The glass and polycarbonate components were throughly cleaned and treated with a silane primer to enhance adhesion. The components were dried, and free of residual solvents and moisture prior to forming the sandwich. The sandwiched laminate was bagged and autoclaved at a temperature of 205° to 255° F. under 10 atmospheres of pressure for a period of about 90 minutes. The laminate was cooled quickly to room temperature. The laminate was used as a target and a 45 calibre bullet from a handgun was fired at the laminate three times. No delamination occurred although the glass shattered. The ionomer resin film remained laminated to the polycarbonate and glass surfaces.
EXAMPLE 3
Laminates 75 mm square were prepared following the procedure and using like components specified in Example 2 were prepared. The resultant laminates were placed in boiling water. The laminates did not lose integrity after two hours in boiling water. Small bubbles did develop about the perimeter the laminates; however, visibility was only marginally impaired around the perimeter.
On the basis of the foregoing examples, ionomer resin films may be substituted for polyurethane and polyvinyl butyral in laminated safety glass, at a substantial savings in cost. The best primer for the polycarbonate/ionomer resin interface is Dow Z-6020. Other primers could prove satisfactory.
EXAMPLE 4
A 30 cm by 30 cm laminate comprising an 0.25 mm thick ionomer resin film sandwiched between 1 mm thick chemically strengthened glass and a 1 mm thick aluminized steel sheet following the procedure set forth in Example 2. The laminate was cycled between -20° F. to 160° F., 10 times and did not undergo delamination.
EXAMPLE 5
A 30 cm by 30 cm laminate comprising a 3 mm thick clean acrylic sheet sandwiched between two 1.4 mm thick ionomer resin films made from SURLYN 1707 which in turn are sandwiched between 3 mm thick sheets of chemically strengthened glass was prepared following the procedure of Example 2. A long 22 caliber rifle bullet was fired at the resulting laminate from a distance of 35 feet, and no penetration resulted.
EXAMPLE 6
A 30 cm by 30 cm laminate comprising chemically strengthened glass and ionomer resin film made from SURLYN 1707 sandwiched in the order shown in FIG. 9 was prepared following the procedure of Example 2. The lamina was laid up in the following order, starting with the target side: a 2.5 mm thick lamina of chemically strengthened glass, a 5 mm thick lamina of ionomer resin film, or 12 mm thick lamina of chemically strengthened glass, a 5 mm thick lamina of ionomer resin film, a 12 mm thick lamina of chemically strengthened glass, a 5 mm thick lamina of ionomer resin film and a 1 mm thick lamina of chemically strengthened glass. All surfaces were cleaned and treated with a silane primer to enhance adhesion. In this instance, the laminate was autoclaved under vacuum at a temperature between 205° F. and 285° F. at 10 atmosphere pressure for a 2.5 hours. After cooling quickly, the resulting laminate was clear and used as a target with the mass of glass facing in the direction of fire. A 0.357 magnum handgun using 158 grain metal painted ammunition of Remington was fired at the laminate. No penetration occurred after three shots were fired in a triangular pattern. The 1 mm thick glass sheet did splinter but remained laminated.
This example was repeated substituting 6 mm thick cast sheets of ionomer resin for the 5 mm thick ionomer resin lamina and in place of the 1 mm thick glass spall sheet. The resultant laminate was not penetrated when fired on as above, and only a slight bulge appeared on the spall sheet.
An organic diamine was selected from the group of diamines listed below and was mixed with a partially neutralized Surlyn 1707 resin. The mixture was added to the resin port of a small extruder (Wayne Machine Co., 7-in extruder, with a nine inch die). The extruding barrel was maintained at 325°-400° F. A 50 to 60 mil film was extruded and cut into six inch squares stacked to about one-half inch thickness and laminated between two primed one-fourth inch glass plates in an autoclave at 255° F. for three minutes under 150-200 psi pressure in a vacuum. The final ionomer layer was optically clear and one-half inch or more in thickness with a light transmitance over 50%.
The following amines in the weight percents given were combined with Surlyn 1707. For each amine, excellent optical clarity was achieved.
______________________________________Amine Weight Percent______________________________________(a) 1,4-butamediamine 1(b) 1,6-hexanediamine 1(c) BAC 1(d) isophorone diamine 3______________________________________
Similarly, following the aforementioned procedure, a mixture of zinc ionomer or an ionomer neutralized with both zinc and sodium ions may be utilized in place of the sodium ionomer. The mixture of ions produces an ionomer having greater impact resistance.
The ionomer may be partially neutralized with a metal cation selected from the group consisting of alkali metals, aluminum and zinc. Most preferable are sodium and zinc cation.
Other ionomers which may be utilized in connection with the invention are disclosed in co-pending application Ser. No. 642,042 filed Aug. 17, 1984, which is incorporated herein by reference.
The preferred organic amines which are utilized as the metal cation are selected from the group consisting of 1,3-diaminomethyl xylene, isophorone diamine and a monocyclic compound of the formula: ##STR1## wherein: R" and R'" represent hydrogen or lower alkyl;
Z is 0-5;
W is 0-4; and
X is 0-4, with the proviso that together X and Y equal 4.
Aliphatic diamines and triamines such as 1,4-butanediamine, and diethylenetriamine are preferably use in combination with sodium or zinc ionomers.
It is to be understood that the foregoing examples are given for the purpose of illustration and that any other suitable glass, ionomer resin, reinforcing plastic or the like could be used provided that the teachings of this disclosure are followed.
The basic building block of this invention, namely a laminate comprising a sheet of glass laminated to an ionomer resin film, may be used in multiples to achieve nearly any desired strength. This is illustrated in FIG. 9, wherein lamina of varying thickness of glass are sandwiched with lamina of varying thickness of ionomer resin film. By varying the number and the thickness of the lamina of glass and ionomer resin film, always, however, laminating in the alternative order shown in the Figure, it is possible to produce laminates having resistance to exceptionally large force. The principles of this invention may also be applied to curved laminated articles, such as windshields and face masks. The laminates shown in FIGS. 1-9 are flat merely for purposes of facilitating illustration. Where transparency is not critical, the bonding techniques taught herein may be used for laminating metal as well as glass such as illustrated in FIG. 8.
This 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.
Having thus described the invention, | 4y
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FIELD OF THE INVENTION
[0001] This invention relates to securing deformable hoses on rigid tubular fittings such as those found in automobile engines to provide a fluid tight seal between a hose and a fitting. More particularly, the invention relates to a hose clamp retention device to position and retain a clamp on a hose ready to be activated after the hose has been positioned over a rigid tubular fitting.
BACKGROUND OF THE INVENTION
[0002] Hose clamps have been designed in a great variety of forms. One type is a clamp of spring steel made to have a diameter slightly smaller than that of the outside diameter of the hose. As a result, when the clamp is pre-loaded by deforming it to enlarge the clamp, there will be stored energy in the clamp which can be released to apply a compressive radial force to hold the clamp on the hose.
[0003] A variation of the pre-loaded type is a clamp made of spring steel and shaped to be enlarged into an open position at the point of manufacture to store energy. The clamp is retained in this open condition either by a built-in restraining structure or by a keeper in the form of a clip. In use, the clamp is released over the hose to clamp the hose.
[0004] It has become common practice to pre-assemble clamps on a hose and provide this assembly to the automobile assembly line. The clamps are typically placed on the hose and either glued in position or attached to the hose with rivets at a point diametrically opposite the restraining structure or held in place by a clamp retention device which engages the hose to hold the clamp in place. The clamp is then in place to be released into a condition to apply a radial compressive load on the hose.
[0005] In order to position a clamp retention device on a hose, the clamp retention device itself will have a retainer comprising a retainer belt with free ends which couple together to locate on the hose in side-by-side relationship with a clamp locator that holds the clamp. Such a clamp retention device is described in U.S. Pat. No. 5,915,739.
[0006] The clamp retention device is preferred over attaching the clamp directly to the hose because of difficulties which arise in aligning the clamp and ensuring that the clamp is orthogonal to the hose. However, a clamp retention device which comprises both a clamp locator and a retainer belt occupies space along the length of a hose and this is not always available where a hose fitting is used in a crowded environment.
[0007] An object of this invention is to provide alternative means for securing a hose clamp retention device to a hose which obviates the need for a retainer belt.
SUMMARY OF THE INVENTION
[0008] In accordance with the invention, there is provided a clamp retention device for positioning an open, generally cylindrical hose clamp on a hose. The retention device extends generally about a longitudinal axis and has at least one locator for cooperating with the clamp and coupling the clamp to the retention device to hold the clamp disposed about said longitudinal axis. The retention device may further includes at least one preformed perforation to receive therethrough at least one fastener for attaching the retention device to the hose. Preferably, the retention device has a body with at least one dependent tab integrally formed with the body and extending longitudinally from the body at one end thereof for receiving therethrough fastening means, preferably in the form of a wire staple or a rivet.
BRIEF DESCRIPTION OF DRAWINGS
[0009] In order to better understand the invention, a preferred embodiment is described below with reference to the accompanying drawings, in which:
[0010] [0010]FIG. 1 is a perspective view of a hose clamp retention device according to the invention shown assembled with a clamp from one side;
[0011] [0011]FIG. 2 is a similar view to FIG. 1 from the other side;
[0012] [0012]FIG. 3 is a similar view to FIG. 1 showing the hose clamp retention device without the associated clamp;
[0013] [0013]FIG. 4 is a top plan view of the hose clamp retention device of FIG. 3 (without a staple);
[0014] [0014]FIG. 5 is a front side elevation view of the hose clamp retention device of FIG. 3 (without a staple);
[0015] [0015]FIG. 6 is an exploded assembly view of the hose clamp retention device of FIG. 1, assembly on a hose;
[0016] [0016]FIG. 7 is a perspective view showing the components of FIG. 6 assembled together on a rigid tubular fitting;
[0017] [0017]FIG. 8 is a cross-sectional view of the assembly of FIG. 7, drawn online 8 - 8 of FIG. 7;
[0018] [0018]FIG. 9 is a similar view to FIG. 3 of a first alternative embodiment of a hose clamp retention device made in accordance with the invention; and
[0019] [0019]FIG. 10 is a similar view to FIG. 3 of a second alternative embodiment of a hose clamp retention device made in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Reference is first made to FIGS. 1 and 2 which illustrate an injection molded hose clamp retention device indicated generally by the numeral 20 and containing an exemplary hose clamp indicated generally by the numeral 22 . The hose clamp is generally cylindrical and is of the pre-stressed type incorporating a latch structure 24 to hold the clamp in an open position for engagement over a hose. It will be evident from the following description that the hose clamp 22 is exemplary of a variety of clamps and that the retention clamp 20 can be used with such clamps.
[0021] The retention device 20 shown in FIGS. 3 to 5 without a clamp consists essentially of a retainer body 26 made of propylene or nylon and which extends generally about a longitudinal axis 28 . The body 26 is generally C-shaped and is proportioned to be a snap-fit on the clamp 22 . C-shaped body 26 has a pair of inwardly extending projections 30 , 32 provided on an inwardly facing surface of the body 26 for engagement in respective openings 34 , 36 formed in the clamp 22 and shown in FIG. 6. The retainer body 26 also has a pair of projecting cams 38 , 40 disposed on the C-shaped body 26 at opposite free ends thereof (best seen in FIG. 5). The cam 38 is centrally disposed in the retainer body 26 and locates against a shoulder 42 defined by an opening 44 formed in the clamp 22 , as best seen in FIG. 6 while the cam 40 is disposed to one side of the retainer body 26 and locates against shoulder 45 formed by an undercut in the side of the clamp 22 , as best seen in FIG. 2. Consequently, when the clamp 22 is engaged in the retainer body 26 by deforming the body to receive the clamp, the projections 30 , 32 and cams 38 , 40 locate the clamp angularly with respect to the body to restrict radial movement of the clamp 22 . As mentioned previously, the exemplary clamp 22 is in an expanded or open condition retained in this form by the latch structure 24 ready to be released into a deployed position. However, other types of clamps can be accommodated for conventional actuation.
[0022] In order to limit relative longitudinal movement between the clamp retention device 20 and a hose 46 disposed longitudinally inside the clamp 22 as shown in FIG. 7, the body 26 also has a pair of oppositely disposed, radially inwardly extending locating tabs 48 , 50 . The locating tabs 48 , 50 have an L-shaped cross-section and extend longitudinally from the body 26 at one end thereof so that when assembled with the hose 46 with one end of the hose proud of the body 26 to extend a short distance therefrom, the hose 46 will abut against the locating tabs 48 , 50 .
[0023] A third locating tab 52 of similar shape and orientation to tabs 48 , 50 is disposed therebetween so as to lie diametrically opposite to the latch structure 24 of the clamp 22 . The tab 52 likewise extends longitudinally from the body 26 on the same side as the locating tabs 48 , 50 and has a radially inwardly extending lip portion 54 for location against the free end of the hose 46 to limit relative longitudinal movement between the clamp retention device 20 and the hose 46 .
[0024] A longitudinally extending portion 56 of the locating tab 52 has a pair of spaced preformed perforations 58 formed therein as clearly shown in FIG. 4. The separation between the perforations 58 is selected to receive the free ends of a U-shaped staple 60 (FIG. 1, 6) prior to bending the legs of the staple over the inside surface 62 of the hose 46 . The hose clamp retention device 20 is shown assembled with a clamp 22 on a hose 46 in FIG. 7 where it will be seen that the staple 60 has penetrated the wall of the hose 46 .
[0025] In order to facilitate penetration of the hose 46 with the staple 60 , the locating tab 52 is radially inwardly disposed on the body 26 to lie closer to the longitudinal axis 28 . The radial separation between the locating tab 52 and the interior surface of the body 26 is small, about the thickness of the band comprising the clamp 22 as seen most clearly in FIG. 8. The tab 52 is thereby adapted to lie adjacent to the exterior cylindrical surface of the hose 46 while the locating tabs 48 , 50 are somewhat spaced from the exterior cylindrical surface of the hose 46 .
[0026] Because the hose clamp retention device 20 is preferably molded from synthetic plastic material, the locating tabs 48 , 50 , 52 are integrally formed during molding. The perforations 58 may be preformed during the molding process so that the material comprising the retention device 20 will not shatter or fracture. The retention device 20 may also be molded from any other suitable material which can be perforated after molding, for example, by drilling, without shattering or fracturing.
[0027] Assembly of the device 20 on the hose 46 will next be described with reference being made to FIG. 7. The hose 46 is received in the device 20 with clamp 22 snapped into the generally C-shaped body 26 . The body 26 extends radially about the clamp 22 with respect to the longitudinal axis 28 of the device such that the clamp is retained within the body 26 . The hose 46 and clamp 22 are selected so that the hose 46 will slide through the clamp 22 as is common in the art. The assembly with the clamp 22 is positioned relative to the end of the hose 46 in a predetermined position limited by the locating tabs 48 , 50 , 52 abutting against the free end of the hose 46 . The hose 46 is then secured to the assembly by means of the staple 60 which is received through the perforations 58 and which penetrates the body of the hose 46 . The stapling of the assembly may be automated and performed in a jig to align staples 60 with the perforations.
[0028] It will be evident that when the hose 46 is engaged over a rigid tubular fitting 64 , drawn in ghost outline in FIG. 7, the position of the clamp 22 on the hose should be such that when the engagement takes place upon release of latch 24 , the clamp 22 will compress the hose 46 between the fitting 64 and the clamp 22 . After the engagement on the fitting 64 is complete, the clamp 22 is deployed in the usual fashion so that the energy stored in the clamp compresses the hose 46 about the fitting 64 .
[0029] The retention device 20 has been described as a one-piece injection molded structure. Clearly, the device can be manufactured differently and take many forms within the scope of the invention. All such variations will be evident to persons skilled in the art and are within the scope of the invention as claimed.
[0030] It will also be appreciated that the preformed perforations may be sized to receive fasteners other than staples, such as a rivet 66 shown in the hose clamp retention device 68 of FIG. 9. The device 68 is otherwise similar to the device 20 and like parts have been identified by like numerals. The hose clamp retention device may also be modified to have a plurality of radially spaced tabs each with respective perforations to receive a fastener to secure the device to a hose. Such a modified hose clamp retention device 70 is shown in FIG. 10 and has a pair of oppositely disposed locating tabs 72 , 74 at one end of the device 70 and disposed radially opposite one another.
[0031] The locating tabs 72 , 74 like the locating tab 52 of the hose clamp retention device 20 of FIGS. 1 to 9 , extend longitudinally from the C-shaped body of the hose clamp retention device in respective longitudinal portions 76 , 78 which terminate in respective radially inwardly extending lip portions 80 , 82 . The longitudinal portions 76 , 78 have respective preformed perforations (not shown) formed therein to receive the free ends of a respective U-shaped staple 84 , 86 . It will be noted that the longitudinal portions 76 , 79 of the locating tabs 72 , 74 are radially inwardly disposed to lie closer to the longitudinal axis 28 , similarly to locating tab 52 . This brings the tabs 72 , 74 closer to lie adjacent to the exterior surface of a hose to which the hose clamp retention device 70 is to be coupled.
[0032] The hose clamp retention device 70 is thereby adapted for retaining larger diameter clamps and hoses.
[0033] Similarly to the hose clamp retention device 20 of FIGS. 1 to 8 , the device 70 has locating projection 30 , 32 (only of which can be seen in FIG. 10) and locating cams 38 , 40 (only one of which can be seen in FIG. 10).
[0034] Still more variations to the hose clamp retention device according to the invention may be made as will be apparent to those skilled in the art within the scope of the appended claims. | 4y
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BACKGROUND OF THE INVENTION
The present invention relates to an anti-bounce device for preventing the multiple shocks of a moving mass after a first shock or impact against another element.
The device of the invention may be used for very different applications. It finds its application more particularly in the field of seismic or acoustic wave sources where a moving mass forcibly strikes a target element against which it is precipitated by gravity and/or drive means. A percussion source for land seismic prospection comprising a mass falling along a guide means towards a target element anchored against the surface of the ground is described in French Pat. No. 2 398 316 and corresponding U.S. Pat. No. 4,205,731. Another, adapted more particularly to use in a borehole, is described in French Pat. No. 2 552 553. The use of drive means for hurling a mass against a target element anchored in a well described in French Pat. No. 2 558 and corresponding U.S. Pat. No. 4,648,478.
When the mass is left free, it generally bounces after impact against the associated target element and then strikes it one of more times with decreasing force. The "signature" of the seismic source, i.e. the shape of the pulses which it emits, comprises then in this case several secondary pulses of decreasing amplitude following the main pulse and this disturbs the seismic recordings corresponding to the seismic reflections from the discontinuities of the sub-soil of the shocks transmitted.
In French Pat. Nos. 1 337 935 and 548313 sound generators are described comprising members vibrating under the effect of the shocks of striking elements hurled towards them, and means for exerting recoil forces which prevent said striking elements from again coming into contact after the first impact.
From the French Pat. No. 2,509,052, and corresponding U.S. Pat. No. 4,505,362 a device is known or preventing multiple shocks on a target element, coupled with the surface of the ground, of a mass guided in its fall by guide means, with these multiple shocks being due to bouncing of the mass after its first impact. This device comprises essentially a deformable element fastened to the guide means and control means adapted for applying the deformable element against the lateral wall of the mass after its first bounce and immobilizing it before it falls again. The control means comprise, for example, a movable member moved radially by the action of a hydraulic cylinder and an impact detector delivering a cylinder control signal.
This device very efficiently stops any falling back of the mass but, because of its transverse position perpendicular to the longitudinal axis of the guide means, its size would not be compatible with the reduced dimensions of boreholes in which the well seismic sources are generally lowered.
SUMMARY OF THE INVENTION
The device of the invention avoids the multiple shocks of a moving mass after its first impact against an object or an element, in all cases where the lateral space about the fall direction is restricted. Contrary to the prior art devices previously mentioned which prevent the moving mass from coming back into contract with the impacted element by blocking it after its first bounce, the device of the invention seeks to prevent bouncing.
It is characterized in that it comprises magnetic means for exerting an intermittent attractive force on the mass which results in applying it against the object and preventing it recoil under the effect of the impact.
The device of the invention avoids in particular the bouncing of a moving mass after a first impact against a target element in contact with geological formations so as to form a seismic source with a "signature" free of secondary pulses.
The magnetic means comprise, for example, at least one permanent magnet, at least one electromagnet, electric current supply means and control means for creating a magnetic force of the same direction as the magnetic force of the permanent magnet or in a direction opposite this force so as to substantially cancel out the attractive force and facilitate separation of the mass.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the device of the invention will be clear from the following description of embodiments given by way of non limitative examples, with reference to the accompanying drawings in which:
FIG. 1 is a sectional view of a device associated with any target element;
FIG. 2 is a top view of the same device comprising permanent magnets disposed in a ring; and
FIG. 3 is an example of applying the device where the magnetic force is used for avoiding bouncing of a mass after impacting a target element anchored in a well.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The device of the invention is associated with a target element 1 adapted for receiving the impacts of a moving mass 2. It comprises magnetic means associated with the target element 1 for exerting an intermittent attractive force on the mass 2. The target element 1 comprises a recess 3 housing at least one magnetic assembly formed of a permanent magnet 4 and an electromagnet 5 connected by a supply cable 6 to a DC source 7, via a two position switch 8 allowing the direction of the magnetizing current to be modified at will. The characteristics of the permanent magnet 4 and of the electromagnet 5 of each magnetic assembly and their relative arrangement are chosen so that, in a first position of the switch, 8 the magnetic forces which they exert are of the same direction and attract the mass 2 and in the second position of the same switch 8 they are opposite one another and substantially cancel each other out.
The number and arrangement of the magnetic assemblies are chosen as a function of the form of the target element 1 and of the mass 2. In the case where the target element 1 and the mass 2 have a cylindrical shape, several magnetic assemblies may be disposed symmetrically with respect to the moving direction of the mass 2. Preferably, an even number of permanent magnets (2) is associated with the mass, disposed so that the magnetizing axes of two adjacent magnets are reversed with respect to each other. From the point of view of the mass 2, there will be alternation of north N and south S poles. This arrangement promotes closure of the magnetic force lines between the permanent magnets 4.
An electromagnet 5 is disposed against each permanent magnet 4 so that the direction of the magnetic field created by the flow of the electric current and that of the permanent field are parallel. The coils of the different electromagnets are connected in series for example and so that the flow of the electric current creates, in two adjacent electromagnets 5, magnetic fields opposite in direction to each other.
Depending on the position of the switch 8, an electric current flow is created such that the magnetic forces of a permanent magnet 4 and of the electromagnet 5 of each magnetic assembly are added together, or are subtracted from each other.
The device operates in the following way. When the mass 2 moves towards the target element 1, an electric current is imposed in a direction such that the magnetic forces of the permanent magnets 4 and of electromagnets 5 are added together. The resultant attractive force attracts the mass 2, applies it against the target element 1 and thus prevents any possible bouncing.
After the impact, when the mass 2 is to be brought back to its initial starting position, the direction of the electric current is reversed so that the magnetic forces of the permanent magnets 4 and of the electromagnets 5 cancel each other out and so that the resultant attractive force is cancelled out. The mass 2 may then be separated from the target element 1.
In the example of application shown in FIG. 3, the anti-bounce device is used for preventing the bouncing of a mass 2 against a target element 1 coupled with the wall of a well 9. Mass 2 moves in a straight line inside an elongate body 10 lowered into well 9 at the end of an electric supply and support cable 11 comprising electric supply lines. Towards its end opposite cable 11, body 10 is associated with anchorage shoes 12. These shoes are fixed to the ends of the rods 13 of hydraulic cylinders (not shown) disposed radially in a compartment 14 containing a hydraulic control system. Such a hydraulic system is described in the above French Pat. No. 2 558 610 and corresponding U.S. Pat. No. 4,648,478. The mass 2 is moved from an impact position in contact with the target element 1 to a set position by lifting means. These means comprise a rigid rod 15 connected to cable 11 by a mechanical and electric connector 16. Rod 15 passes through the upper end wall 17 of the body through an opening and inside, in the cavity 18 where the mass 2 moves, it is fixed to retractable fastening means. The means comprise a rigid support 19. Two hooks 20 are pivotable about pins 21 fixed to support 19 between a closed position and a spaced apart position (shown with broken lines in FIG. 3). On its upper face, the mass 2 has a head 22 with a circular groove 23 where the tips of the hooks 20 may be engaged in the closed position and thus make mass 2 fast with the fastening support 19. The hooks 20 are pivoted towards their spaced apart position by energizing electromagnets 24 with movable cores 25. The cores 25 are disposed radially in the pivoting plane of hooks 20 and are connected thereto. A return spring R tends to maintain the hooks 20 in their closed position.
The electromagnets 24 are energized through conductors 26 passing in the axis of the rigid rod 15 and are connected in connector 16 to conducting lines 28 of the electric supply and support cable 11. The electric conductors 6 for supplying the electromagnets 5 of the anti-bounce device are led up through a channel formed in the side wall of body 10 towards the end wall 17 where they are connected to a first end of an electric cable 27 would in a spiral about the rigid rod 15. At its opposite end, the electric cable 27 penetrates into connector 16 where it is connected to electric lines 28 of the electric supply and support cable 11. The electric conductors 6 and 26 are connected so that the electromagnets 5 of the anti-bounce device are connected in series with the coil of the electromagnet 24. Other electric conductors (not shown) transmit electric currents and control signals to the hydraulic system.
At the opposite end of the electric supply and support cable 11, conductors 28 are connected to the electric current source 7 (cf. FIG. 1) via the switch 8. Conductors 6 and 26 are interconnected so that in a first position of switch 8, the electromagnets 24 move hooks 20 away from each other and at the same time the electromagnets 5 exert an attractive force on the mass 2. In the second position of switch 8, these same electromagnets 5 push the hooks 20 back towards their closed up position and exert a repelling force on the mass 2.
With the well source anchored in the well by moving the anchorage shoes 12 apart, the switch 8 is placed in its second position and the cable 11 is released so that the rigid support 19 moves down along cavity 18 towards the mass 2 which is in its position against the target element 1 (low position). Coming into contact with head 22, hooks 20 move apart and are engaged in the groove 23 thereof.
By a tractive force exerted on the electric supply and support cable 11, support 19 and mass 2 which is fastened thereto are raised to a high position.
At the moment chosen for tripping, the switch 8 is placed in its first position. The electromagnets 24 move the hooks 20, which retain the released mass 2, away from each other, the mass 2 falls along the cavity 18 and, coming into contact with the target element, it is subjected to the electromagnetic attractive force developed by the electromagnets 5. The electromagnets are chosen as a function of the kinetic energy acquired by the mass 2 at the end of its fall for preventing any possible bouncing.
Without departing from the scope of the invention, permanent magnets may be added to the well source of FIG. 3, such as magnets 5 shown in FIG. 1 for increasing the magnetic attractive force undergone by mass 2. In the most general case, the association of permanent magnets 4 with electromagnetic means 5 is in no wise obligatory. The magnetic attractive force may possibly be created by electromagnetic means alone.
Without departing from the scope and spirit of the invention, the device of the invention may be applied to any seismic percussion source whatever. | 4y
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CROSS-REFERENCE
This is a continuation of application Ser. No. 07/348,458, filed on 05/08/89, now abandoned, of Lothar P. Stiberth, James R. Miller, and Sudhendra V. Hublikar, for "TIRE CORD ADHESIVE LATEXES CONTAINING AMINO ACRYLATE POLYMERS."
FIELD OF THE INVENTION
The present invention relates generally to copolymers or overpolymers of styrene-butadiene rubber and an amine substituted alkyl acrylate of the formula I ##STR1## R 1 is hydrogen, or alkyl having 1 to 4 carbon atoms, and preferably R 1 is hydrogen or methyl, and most preferably R 1 is methyl; R 2 is an alkyl having from 1 to 8 carbon atoms, and preferably 2 to 4 carbon atoms; and R 3 and R 4 are the same or different and are hydrogen, aliphatic having 1 to 8 carbon atoms, or aromatic or aliphatic substituted aromatic having 6 to 8 carbon atoms, or together with the nitrogen are heterocyclic having 3 to 8 carbon atoms, or oxygen, sulfur, and/or halogen derivatives of the same; and preferably R 3 and R 4 are hydrogen or aliphatic having 1 to 4 carbon atoms where one may be hydrogen but not both; and most preferably R 3 and R 4 are both ethyl, or R 3 is butyl and R 4 is hydrogen. These polymers are used as a latex in a resin formulation to promote adhesion between an organic substrate and an unsaturated binder such as a rubber. The polymers are made in an emulsion polymerization process.
BACKGROUND
Unsaturated polymers, such as the natural and synthetic rubbers are often reinforced with fibers or textiles made from organic or inorganic fibers. Examples of such reinforcing substrates include cords, fibers and textiles made of carbon, nylon, aramid, cotton, silk, rayon, wool, polyester, glass and steel. The unsaturated polymers include, for example, polymers made from butadiene, styrene, isoprene, isobutylene, acrylonitrile, ethylene, propylene, chloroprene, and derivatives of the same. The applications for such reinforced polymers include tires, hoses, pressure vessels, and other such fiber-reinforced articles.
It is often a problem to achieve good adhesion between the reinforcing substrate and the unsaturated polymer matrices. In the past, the adhesion problem has been addressed by use of an adhesion promoter. One such adhesion promoter is a resorcinol-formaldehyde-latex (RFL) which has been widely used and modified since its invention by Charch. Its use was taught in U.S. Pat. No. 2,211,945. As the term RFL indicates, the resin is usually resorcinol-formaldehyde (RF) copolymer. However, other resins such as acrylic polymers, phenol polysulfides, phenol-formaldehyde type polymers may be used. Examples of these are taught in U.S. Pat. No. 4,472,463; Great Britain 2,147,303, and U.S. Pat. No. 4,448,813.
The latex in the RFL system is usually butadiene/styrene/vinyl pyridine polymer. This polymer has been the industry standard since it was invented by Mighton, U.S. Pat. No. 2,561,215. The RFL is applied as a coating to the substrate, which is subsequently heat-treated to cure (i.e., "crosslink") the RFL resin. The unsaturated elastomer from the latex, however, remains uncured. The matrix elastomer is then applied to the RFL-treated substrate and the composite is subsequently cured to form the product.
The present invention provides a heretofore unknown latex composition which acts in a resin formulation as an adhesion promoter between organic substrates and unsaturated polymers. The latex can be a dispersion of a copolymer of styrene and butadiene with an amine substituted alkyl acrylate; or it can be a dispersion of a shell/core polymer where the core is a styrene/butadiene copolymer and the shell comprises a copolymer of the styrene, butadiene, and the acrylate. The composition is generally formed in an emulsion copolymerization. The composition is then used in a resin/latex formulation to form a coating of reinforcing substrates and thereby provide adhesion between the reinforcing substrate and an unsaturated polymer matrix.
SUMMARY OF THE INVENTION
An adhesion promoter is provided which is the copolymerization product of styrene, butadiene and an amine substituted alkyl acrylate. The amine substituted alkyl acrylate has the general Formula I ##STR2## wherein R 1 is hydrogen, or alkyl having 1 to 4 carbon atoms, and preferably R 1 is hydrogen or methyl, and most preferably R 1 is methyl; R 2 is an alkyl having from 1 to 8 carbon atoms, and preferably 2 to 4 carbon atoms; and R 3 and R 4 are the same or different and are hydrogen, aliphatic having 1 to 8 carbon atoms, or aromatic or aliphatic substituted aromatic having 6 to 8 carbon atoms or together with the nitrogen are heterocyclic having 3 to 8 carbon atoms, or oxygen, sulfur, and/or halogen derivatives of the same; and preferably R 3 and R 4 are hydrogen or aliphatic having 1 to 4 carbon atoms where one may be hydrogen but not both; and most preferably R 3 and R 4 are both ethyl or R 3 is butyl and R 4 is hydrogen.
The styrene is present from about 0 to about 30 percent, preferably from about 15 to about 28 percent, and most preferably from about 20 to about 25 percent; while the butadiene is present from about 55 to about 97 percent, preferably from about 65 to about 80, and most preferably from about 69 to about 78 percent, based on the total weight of the monomers in the adhesion promoter. The amine substituted alkyl acrylate is present in an amount of about 1 to about 15, preferably from about 2 to about 12, and most preferably from about 3 to about 10 percent by weight based on the total weight of the monomers in the adhesion promoter.
The polymer is produced as a latex by emulsion polymerization. It is used in a resin/latex formulation to form a substrate coating which acts as an adhesion promoter which yields excellent adhesion as measured by ASTM test D-2138. The adhesion promoter can be used with various substrates and elastomers.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to a latex polymer which acts in a resin formulation between an unsaturated polymer matrix and a reinforcing substrate. The term "polymer" is used broadly herein to mean either a copolymer or an overpolymer or a shell/core polymer. This polymer is made from 0 to 30 percent, and preferably 15 to 28 percent, and most preferably 20 to 25 percent styrene; 55 to 97 percent, and preferably 65 to 80 percent, and most preferably 69 to 78 percent butadiene; and 1 to 15 percent, and preferably 2 to 12 percent, and most preferably 3 to 10 percent by weight of an amine substituted alkyl acrylate, all percentages, based on the total weight of the monomers.
If the polymer is a shell/core polymer, the shell is a copolymer of the amine substituted alkyl acrylate with the SBR. It is preferred that the amine substituted alkyl acrylate is present in at least 6 percent, and preferably at least about 3 percent of the monomer composition.
The amine substituted alkyl acrylate has a general formula I ##STR3## wherein R 1 is hydrogen, or alkyl having 1 to 4 carbon atoms, and preferably R 1 is hydrogen or methyl, and most preferably R 1 is methyl; R 2 is an alkyl having from 1 to 8 carbon atoms, and preferably 2 to 4 carbon atoms, and R 3 and R 4 are the same or different and are hydrogen, aliphatic having 1 to 8 carbon atoms, or aromatic or aliphatic substituted aromatic having 6 to 8 carbon atoms, or together with the nitrogen are heterocyclic having 3 to 8 carbon atoms, or oxygen sulfur, and/or halogen derivatives of the same; and preferably R 3 and R 4 are hydrogen or aliphatic having 1 to 4 carbon atoms where one may be hydrogen but not both; and most preferably R 3 and R 4 are both ethyl, or R 3 is butyl and R 4 is hydrogen. Methacrylate amino esters are preferred over acrylate amino esters, because they exhibit more favorable, higher combining ratios during copolymerization. Increasing the number of carbon atoms in the groups attached to the nitrogen atom of the acrylic esters serves to decrease the rate of hydrolysis of the ester, especially in alkaline media. This is believed to be an advantage in the invention as practiced. Specific examples of preferred acrylates include diethyl amino ethyl methacrylate, and monobutyl amino ethyl methacrylate.
The polymers are latex polymers produced by emulsion polymerization When the random copolymer is produced, all monomers are charged at the same time to the reactor. When the shell-core polymer is produced, polymerization is first initiated with only the styrene and butadiene; then the amine substituted alkyl acrylate is added at from about 32 to about 97 percent conversion of the core polymer and preferably from about 45 to about 60 percent conversion. Suitable polymerization surfactants could be anionic surfactants including, for example, potassium oleate and sodium lauryl sulfate. Nonionic and cationic surfactants as are known in the art could also be used. Free radical catalysts such as an alkanoyl, aroyl, alkaroyl, or an aralkanoyl diperoxide, a monohydroperoxide, or an azo compound, a peroxy ester, a percarbonate, a persulfate, or any other suitable free radical-type initiator are used in an amount of from about 0.03 to about 0.3 parts per hundred parts monomer. Examples of specific initiators include potassium persulfate, sodium persulfate, ammonium persulfate, benzoyl peroxide, lauroyl peroxide, diacetyl peroxide, cumene hydroperoxide, methyl ethyl ketone peroxide, diisopropylbenzene hydroperoxide, 2,4-dichlorobenzoyl peroxide, naphthoyl peroxide, t-butyl perbenzoate, di-t-butyl perphthalate, isopropyl percarbonate, acetyl cyclohexane sulfonyl peroxide, disecondary butyl peroxydicarbonate, t-butyl peroxyneodecanoate, dinormal propyl peroxydicarbonate, azo-bisisobutyronitrile, alpha, alpha'-azodiisobutyrate, 2,2'azo-bis-(2,4-dimethyl valeronitrile), paramethane hydroperoxide, 4-pinane hydroperoxide, and the like. Initiation may also be by UV or other radiation.
The polymerization is generally run in a 1000-3500 gallon batch reactor at a temperature of about 10° C. to about 50° C. and a pressure of about 50 psi to about 60 psi to about 100 percent conversion. Optimally, the polymerization product is a latex having a particle size of about 40 to about 140 nm, and preferably 80 to about 130 nm. The polymer is usually at a concentration of about 40 percent in the latex.
The resin/latex adhesive is prepared by mixing the adhesion promoting latex with a resin. In the preferred case, the resin is a resorcinol formaldehyde (RF) resin. It is believed that the latex polymer of the present invention will be effective in promoting adhesion in any resin formulation wherein styrene/butadiene/vinyl pyridine has been effective in promoting adhesion. Examples of other such suitable resins include acrylic polymers, phenol polysulfide polymers and copolymers from formaldehyde and hydroxy benzenes such as xylenols and cresols. The dry solids ratio of latex polymer to resorcinol-formaldehyde (L/RF ratio) is from about 1 to about 10, and preferably from about 1 to about 7, and most preferably from about 2 to about 5. The most preferable latex/resin ratio may vary depending on the reinforcing substrate, the resin, and the unsaturated polymer matrix to which it must be adhered.
The reinforcing substrate is dipped into the resin/latex adhesive and the excess is removed. The coated substrate is dried, and then cured at 150° C. to about 250° C., and preferably from about 175° to about 230° C. for 30 seconds to 10 minutes, depending on the temperature, and preferably from about 1 to about 4 minutes.
The treated substrate is then embedded into the unsaturated polymer which already contains curing agents, etc. This composite is then cured under pressure at a temperature of from about 100° to about 200° C., and preferably from about 130° to about 180° C. for 10 to about 30 minutes, depending on the temperature, and the thickness of the composite.
Suitable substrates include cords, fibers and textiles made of cotton, rayon, silk, wool, polyester such as poly(ethylene terephthalate), aliphatic and aromatic polyamides such as Nylon 66 and poly(phenylene terephthalamide), carbon, glass and steel. As is well known, some of the reinforcing substrates give best results if pretreated, before coating with the resinlatex composition of this invention, e.g., poly(ethylene terephthalate) "polyester", i.e., fibers treated with a polyisocyanate as taught in U.S. Pat. Nos. 3,307,966 and 3,226,276 which are incorporated herein by reference as if fully set forth herein. Examples of preferred substrates include those commonly used to reinforce rubber such as rayon, nylon, polyester, glass, and "Kevlar" (a poly(phenylene terephthalamide) sold by Du Pont de Nemours, Inc.)
The unsaturated polymer matrices include, for example, polymers made from butadiene, styrene, isoprene, isobutylene, acrylonitrile, ethylene/propylene, chloroprene, derivatives of the same, and other such polymers. The resin latex formulation promotes adhesion between the substrate and an unsaturated polymer matrix. By "unsaturated polymer" in this instance it is meant a polymer having unsaturation in the backbone or pendant groups and not aromaticity. This is most generally olefinic unsaturation. It is believed that the adhesion promoter of the present invention is broadly applicable for use with all sorts of polymers having olefinic unsaturation. Examples of specifically preferred unsaturated polymers include styrene/butadiene, natural rubber or polyisoprene, polychloroprene, butadiene/isobutylene copolymer, and ethylene/propylene/butadiene terpolymers. The adhesion promoter of the present invention results in excellent adhesion as measured by ASTM Test D-2138.
In this test, adhesive failure can occur at two interfaces: between the substrate and the RFL, and between the RFL and the elastomeric matrix. In addition, cohesive failure may occur in the substrate, the RFL or the elastomeric matrix. Traditionally, by excellent adhesion, it is meant not only that the failure load is high but also that primary failure does not occur at either interface nor does it occur cohesively in the RFL. In such a situation then, interfacial bond strengths as well as the cohesive strength of the RFL are greater than the cohesive strengths of either the substrate or the elastomeric matrix.
In all these examples, failure in the ASTM D2138 test occurred primarily within the elastomeric matrix. This means that adhesion between the elastomer matrix and the RFL, adhesion between the textile substrate and the RFL, and the cohesive strength of the RFL are all greater than the measured and reported adhesion value.
The invention will be better understood by reference to the following examples.
EXAMPLE 1
Preparation of SBR-DEAM and SBR-VP Latices
A random terpolymer of butadiene, styrene, and diethylaminoethylmethacrylate (DEAM) was prepared using the recipe in Table I.
TABLE I______________________________________Ingredient Parts______________________________________Butadiene 70.0Styrene 20.0DEAM 10.0Potassium Oleate 5.0Potassium Hydroxide 0.05Trisodium Phosphate (Na.sub.3 PO.sub.4.12H.sub.2 O) 0.5Sodium Bicarbonate 0.2Sodium Hydrosulfite (Na.sub.2 S.sub.2 O.sub.4) 0.1Dispersing Agent 1.5t-Dodecyl Mercaptan 0.36Sodium Persulfate 0.35Water 140.00______________________________________
Aqueous stock solutions were prepared with one or more of the following ingredients: potassium oleate, potassium hydroxide, trisodium phosphate, sodium bicarbonate, sodium hydrosulfite, and sodium persulfate. All stock solutions and the water were purged with dry nitrogen gas before use.
Potassium oleate, potassium hydroxide, trisodium phosphate, sodium bicarbonate, dispersing agent, some distilled water, styrene and DEAM were all charged into the batch reactor. The reactor was sealed and the butadiene gas was introduced. Sodium hydrosulfite was added and the reactor was introduced into a constant temperature water bath at 50° C. and the contents were continuously stirred. After 10 minutes, t-dodecyl mercaptan was added, and 30 minutes later, sodium persulfate was added. After about 30 hours, 90 percent or more of the monomers had been converted to polymer. The reactor was removed from the bath and the contents (SBR-DEAM latex) were removed.
A butadiene-styrene-vinylpyridine (SBR-VP) latex was prepared using the recipe in Table I, except that 2-vinylpyridine (VP) was substituted for DEAM.
Preparation of Resorcinol-Formaldehyde-Latex (RFL)-A
RFL formulations were prepared with SBR-DEAM and SBR-VP latices using the formulation in Table II.
TABLE II______________________________________ Wet Dry______________________________________Part AResorcinol-formaldehyde resin (70%) 14.24 9.97Ammonia (28%) 28.94 --Sodium Hydroxide 0.28 0.28Acrylic latex (37%) 29.05 10.75Water 145.53 --Part BLatex (41%) (SBR-DEAM or SBR-VP) 166.66 68.33Natural Rubber latex (62%) 12.35 7.66Water 48.51 --Part CFormalin (37%) 8.14 3.01Water 31.41 --Total 485.11 100.00______________________________________
Part A was first prepared. Although commercial resorcinol-formaldehyde (RF) resin was used in this case, it is well known that RF resin can be prepared in-situ by reacting resorcinol with formaldehyde. The use of the acrylic latex, to protect the SBR type latex from environmental attack, has been documented by Solomon in U.S. Pat. No. 3,968,295 which is incorporated herein by reference as if set forth herein.
Part B was then prepared. The addition of natural rubber latex to the formulation is not necessary for RFLs prepared from SBR-DEAM to act as effective adhesion promoters. Part A was then added to Part B and was well mixed.
Part C was prepared and was added to the mixture of Parts A and B. The RFL was then used within 24 hours.
RFL-A was prepared using the formulation in Table II. RFL-B was prepared in a similar way to RFL-A but without the acrylic or the natural rubber latices.
Preparation of Isocyanate-Epoxide Coating (I) Mixture
As is well known in the art, textiles made with poly(ethylene terephthalate) (PET) fibers have to be treated with an IE coating prior to RFL treatment. The IE formulation in Table III was used for this purpose.
TABLE III______________________________________Ingredient Parts______________________________________Phenol-blocked methylene bis(phenyliso- 3.56cyanate)Adduct of glycerol and epichlorohydrin 1.34Anionic surfactant 0.10Water 95.00______________________________________
Treatment of Textiles with EI and RFL Mixtures
Nylon 6,6 (840/2 denier) tire cords were dipped into a bath containing the RFL-A mixture, the excess RFL was removed, and the cords were dried for 2 minutes at 150° C. The dried cords were then baked for 1 minute at 220° C.
Rayon (1650/3 denier) tire cords were treated with the RFL-B mixture using the above procedure.
PET (1000/2 denier) cords were first dipped into the EI mixture, the excess mixture was removed, and the cords were dried for 2 minutes at 150° C. The dried cords were than baked for 1 minute at 240° C. They were then treated with the RFL mixture as outlined above.
Unsaturated Polymer Compounds
The following unsaturated polymer matrices were used for the preparation of H-adhesion test samples. These polymer compounds are typical of those used in tires and other industrial rubber products.
______________________________________Ingredient Parts______________________________________Compound ANatural Rubber 60.00Styrene-butadiene Rubber 40.00Zinc Oxide 2.00Stearic Acid 0.75Oil 15.75Carbon Black 60.00Phenol Formaldehyde Resin 2.50Morpholinothiobenzothiazole Sulfenamide 0.90Sulfur 2.71Compound BNatural Rubber 60.00Styrene-butadiene Rubber 20.00cis-Polybutadiene 20.00Zinc Oxide 2.00Stearic Acid 1.50Oil 10.00Carbon Black 55.00Morpholinothiobenzothiazole Sulfenamide 1.00Sulfur 3.56______________________________________
Adhesion Tests
H-adhesion test samples were prepared and tested according to ASTM D-2138. The results obtained are shown in Table IV.
TABLE IV______________________________________ AdhesionFiber Cord RFL Polymer Latex Mean ±Polymer Denier Type Compound Type Std. Dev.______________________________________Rayon 1650/3 B Compound SBR-VP 34.3 ± 1.3 ARayon 1650/3 B Compound SBR-DEAM 31.2 ± 1.6 ANylon 840/2 A Compound SBR-VP 33.8 ± 3.2 BNylon 840/2 A Compound SBR-DEAM 33.6 ± 1.5 BPET 1000/2 A Compound SBR-VP 31.5 ± 2.6 APET 1000/2 A Compound SBR-DEAM 29.6 ± 2.7 A______________________________________
These results show that SBR-DEAM latex, in an RFL formulation, provides excellent adhesion between typical tire reinforcement materials and unsaturated polymer compounds. The level of adhesion is comparable to that obtained with the SBR-VP latex that is typically used today.
EXAMPLE 2
A terpolymer of butadiene, styrene, and diethylaminoethylmethacrylate (DEAM) was prepared using the recipe in Table V.
TABLE V______________________________________Ingredient Parts______________________________________Butadiene 70.0Styrene 20.0DEAM 10.0Surfactant A 3.0Surfactant B 2.0Potassium Hydroxide 0.05Trisodium Phosphate 0.5Sodium Bicarbonate 0.2Sodium Hydrosulfite 0.1Dispersing Agent 1.5t-Dodecyl Mercaptan 0.36Sodium Persulfate 0.35Water 132.00______________________________________
This recipe is similar to that in Table I except that potassium oleate has been replaced by Surfactant A. Surfactant A is an ammonium salt of sulfated nonylphenoxy poly(ethyleneoxy) ethanol. This formulation uses an additional surfactant--Surfactant B, which is ammoniumlauryl sarcosinate.
The polymerization procedure is almost exactly the one described in Example 1. The only difference is that Surfactant B is added during polymerization in two steps: one-half the quantity at about 8 percent conversion and the other half after reaction is almost complete (greater than 95 percent conversion).
An RFL (RFL-C) was prepared using a formulation similar to that in Table II in Example 1, the only difference being that the only latex used was either SBRDEAM or SBR-VP. In other words, the amount of natural rubber solids in the formulation shown in Table II in Example 1 was replaced with either SBR-DEAM solids or SBR-VP solids, depending on which latex was being used in the formulation. The SBR-VP used in this experiment was manufactured by The BFGoodrich Company and is sold under the brand name Goodrite 2528×10.
1260/2 nylon 6,6 tire cords were treated with RFL-C and embedded in Compound B. 1000/2 denier PET tire cords were treated with IE and RFL-C mixtures and embedded in Compound A. The procedures are described in Example 1. Table VI shows the results of the H-adhesion test (ASTM D-2138).
TABLE VI______________________________________ AdhesionFiber Cord RFL Polymer Latex Mean ±Polymer Denier Type Compound Type Std. Dev.______________________________________PET 1000/2 C Compound SBR-VP 25.3 ± 1.7 APET 1000/2 C Compound SBR-DEAM 27.6 ± 2.1 ANylon 1260/2 C Compound SBR-VP 38.5 ± 2.4 BNylon 1260/2 C Compound SBR-DEAM 34.4 ± 1.5 B______________________________________
These results again indicate that adhesion obtained with SBR-DEAM latex in an RFL formulation is comparable to that obtained with commercially available SBR-VP latex.
EXAMPLE 3
A core-shell SBR-DEAM latex was prepared using the formulation in Table V. The core-shell structure was created by initially introducing only 2.5 parts of DEAM into the reactor. The rest (7.5 parts) was added at about 70 percent conversion. In this case, the core and the shell are composed of SBR-DEAM polymer; the concentration of DEAM in the shell is much greater than that in the core.
Preparation of the RFL, treatment of 1600/2 PET tire cord, adhesion sample preparation and testing were all the same as in Example 2. The adhesion results obtained are shown in Table VII.
TABLE VII______________________________________ AdhesionFiber Cord RFL Polymer Latex Mean ±Polymer Denier Type Compound Type Std. Dev.______________________________________PET 1600/2 C Compound SBR-VP 32.9 ± 2.8 APET 1600/2 C Compound SBR-DEAM 29.7 ± 1.3 A______________________________________
These results indicate that adhesion obtained with core-shell SBR-DEAM latex, in an RFL formulation is also comparable to that obtained with SBR-VP latex.
EXAMPLE 4
A core-shell SBR-DEAM latex was prepared using a formulation similar to that in Table V; the only exceptions were that the levels of butadiene and DEAM were 72.0 and 3.69 parts respectively.
The core-shell structure was created by introducing all of the DEAM into the reactor at 49 percent conversion. Thus, the resulting latex particles are expected to contain a core of SBR polymer which is covered with a shell of SBR-DEAM polymer. Preparation of the RFL, treatment of 1600/2 PET tire cord, adhesion sample preparation and testing were all the same as in Example 2. The adhesion results obtained are shown in Table VIII.
TABLE VIII______________________________________ AdhesionFiber Cord RFL Polymer Latex Mean ±Polymer Denier Type Compound Type Std. Dev.______________________________________PET 1600/2 C Compound SBR-VP 32.9 ± 2.8 APET 1600/2 C Compound SBR-DEAM 30.9 ± 3.0 A______________________________________
These results indicate that adhesion obtained with core-shell SBR-DEAM latex, which contains only about 3.8 percent DEAM in the polymer is also comparable to that obtained with commercially available SBR-VP latex.
While in accordance with the Patent Statutes, the best mode and preferred embodiment has been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims. | 4y
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DESCRIPTION
1. Technical Field
This invention relates generally to devices for removing oil from the surface of water and, in particular, to removal systems for use in the ocean employing a rotating drum with a mesh surface, an internal vacuum system, a system for removing oil from the drum, and a system for transporting the collected oil to a ship.
2. Background Art
Oil drilling and the transportation of oil in tankers has been commonplace in the world's seaways for several decades. While these operations are highly specialized, the hazardous environments in which they are performed can sometimes cause leaks or spills. In economic terms spills are very costly, as they often grow to enormous proportions, containing millions of gallons of oil and spreading over distances measured in miles. In environment terms, spills are catastrophic in that wildlife and their habitats are often irreparably damaged or destroyed. Fast and efficient recovery of the oil is essential to minimizing the economic and environmental damages incurred. To this end, several recovery systems have been developed, such as those represented in U.S. Pat. Nos. 4,555,338, 4,957,636, and 3,968,041.
U.S. Pat. No. 4,555,338 describes a system produced by T. Marchionda. This device employs an alternating clockwise/anticlockwise rotating cylinder, to remove oil from the ocean surface. The cylinder is fabricated with an oil absorbing surface to aid in oil retrieval. The system also utilizes a cage-like apparatus to remove debris and cancel the motion of the waves. A squeegee-like device is employed to remove oil from the cylinder during clockwise rotation and carry it to a collection area. From the collection area, the oil is transported to a storage ship, to which the collection system is attached. While this device may be useful in certain instances, it has some serious limitations. It can not be adjusted for variations in oil consistency and temperature, it operates too slowly to accommodate large spills, and it requires a bidirectional motor for rotation of the pickup roller.
U.S. Pat. No. 4,957,636 describes a device conceived by D. Wilson and J. Trippe. This apparatus consists of two rotating drums whose surfaces contact and remove the oil from the ocean. A squeegee on each drum removes the oil at the front of the apparatus. The oil is then transported to the back of the device and finally to a storage vessel. This device has no protection from floating debris which can clog the system, does not adjust for different types of oil, and is ill suited for operation in the open sea.
U.S. Pat. No. 3,968,041 describes an invention by E. De Voss. This device employs a rotating cylinder to push oil from the surface of the ocean onto a conveyor belt, which extends below the surface of the water. The oil adheres to the surface of the conveyor belt, and is carried to a storage ship. A cylinder on the ship, in rotation opposing the movement of the belt, removes the oil, allowing it to flow into a storage area. While useful in some cases, this apparatus has some serious flaws. It provides no measures to prevent debris, which can clog the machine, from being picked up, is inefficient in separating the oil from the ocean water, and has a complex configuration, making at-sea repairs difficult at best.
It is the intent of the present invention to provide a means for efficiently separating and removing oil from ocean water.
It is a further intent to perform the above mentioned task while diverting floating debris, thus eliminating the risk of obstruction.
It is still further the intent of the present invention to allow for the connection of several components to allow faster retrieval of large spills.
It is yet another intent of the invention to have the ability to retrieve spills containing oil of any consistency or temperature.
These and other objects of the present invention will become apparent upon the consideration of the following description with reference to the drawings referred to therein.
DISCLOSURE OF THE INVENTION
It is the purpose of this invention to efficiently remove oil from the surface of large bodies of water. A large rotating cylinder whose surface is composed of a stainless steel mesh works in conjunction with a vacuum system to separate and remove oil from the water. A squeegee and high pressure water spray system are then employed to remove the oil from the cylinder. The oil is then transported, by Archimedean screws, to the ship to which the apparatus is attached. The rotational energy of the screws is further utilized to drive the revolution of the cylinder. Unique rake tines are provided in front of the rotating drum to divert floating debris around or under the system, thus preventing obstruction of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overhead view of one embodiment of the oil recovery system and the connections therein.
FIG. 2 is an overhead view of an additional floatation device and its position relative to the components in FIG. 1.
FIG. 3 is a diagram showing the side view of the components displayed in FIG. 1.
FIG. 4 is an overhead view of one possible embodiment of the components shown in FIG. 1.
FIG. 5 is a partially cut-away diagram showing the side view of the devices used to attach the components of FIG. 1 to a marine vessel.
FIG. 6 is a close up side view of the vertically moveable attachment between the components of FIG. 1 and the marine vessel.
FIG. 7 is a partially cut-away, close up side view of one method by which the recovered oil can be stored in the marine vessel.
FIG. 8 is a side view of the additional floatation device shown in FIG. 2, further displaying its position relative to the components of FIG. 3.
BEST MODE FOR CARRYING OUT THE DEVICE
A system constructed in accordance with the various features of the invention is shown in the figures generally at 10. The system 10 comprises at least an oil pickup drum 12, ventura vacuum means 18, oil capturing means 20, oil removal means 22, rotational drive means 16, and particle diversion means 62. Each of these components will be described in turn.
The oil pickup drum 12 comprises a support structure and a layer of stainless steel mesh which is secured by said structure. In the preferred embodiment, the support structure comprises endcaps 22 and a center support 24, connected by a plurality of longitudinal beams 26. The endcaps 22 define the outer circumference of said drum 12 and the opposite sides of said drum 12. The center support 24 is located between the endcaps 22 and functions as a stability device for the drum. Longitudinal beams 26, also shown in FIG. 3, are connected at either end to the endcaps 22 and in the center to the center support 24. The beams 26 supply support along the outer circumference of the drum and, due to their hollow construction, help keep the structure 12 afloat. The stainless steel mesh 14 is wrapped around the longitudinal beams 26 and within said endcaps 22. The configuration of mesh 14 used on the drum 12 may be changed, as required by the spill conditions.
The drum 12 is used to capture the oil from the ocean surface. Partially submerged in the water, the drum 12 rotates longitudinally about its axis, as illustrated in FIGS. 1 and 3 by arrow 100. The oil adheres to the stainless steel surface of the mesh 14, while the ocean water passes through holes in the mesh 14. How well the oil clings to the mesh 14 depends upon various conditions, such as the type of oil, its temperature, and water conditions. By using screens 14 with specific parameters, such as pore size and metal thickness, the previously mentioned conditions can be accounted for. This means the amount of oil retrieved can be maximized and the system 10 can operate as efficiently as possible.
The drum 12 is aided in its oil retrieval function by an internal vacuum system 18. The vacuum system 18 employs a high volume water pump (not shown) which must be contained within the ship to which the recovery system 10 is attached. This pump pushes a considerable volume of water through a large diameter pipe 28, which carries the water through the center axis of the drum 12, see FIG. 1. Within the drum the pipe 28 is connected to a ventura tube 30. The combination of the high water volume with the ventura tube 30 creates a vacuum in the drum. Once the water flowing in the pipe 28 has passed through the drum 12, it can be expelled into the ocean, or passed on to the vacuum system for the next drum 12 if several drums 12 have been connected side by side, as in FIG. 4. Threads 86 on pipe 28 allow the construction of such embodiments.
The task of the vacuum system 18 is to pull ocean water through the holes in the mesh 14 while allowing the oil to adhere to the steel mesh 14. The intensity of the vacuum can be adjusted to account for the oil type, temperature, and other conditions. The ventura water system was used in particular because it provides a constant vacuum regardless of how obstructed the pores of the mesh 14 become. By enticing the ocean water to flow through the mesh screen 14 and not stick to it, the vacuum prevents large volumes of ocean Water from being collected by the drum 12, thus improving the efficiency of the system 10.
Since the large diameter tube 28 used by the vacuum system 18 passes through the center of the drum 12, it acts as the axis upon which the drum 12 rotates. The drum 12 is rotatably mounted on the pipe 28, employing steel sleeve 32 and teflon bushing 34 on either side. This connection permits the drum 12 to rotate easily about the axis tube 28.
The oil, having been retrieved by the rotating drum 12, must be removed from the drum surface by the oil capturing system 20. The capturing system 20 consists of a high pressure water spray and a squeegee 36. The squeegee 36 contacts the exterior of the drum 12, scraping the oil off the surface of the drum 12 as it rotates. The oil then runs down the width of the squeegee 36 into a collection trough 38. To aid the squeegee 36 in the removal of oil from the drum 12, a water spray system is included. The spray system comprises a small diameter pipe 40, to which a plurality of spray nozzles 42 are attached. One end of pipe 40 is connected to a high pressure water pump (not shown) that must be contained within the ship to which the oil recovery system 10 is attached. The pipe 40 carries the water from the ship, into the drum 12, and near the inner surface of the drum 12. More specifically, the water is brought close to and parallel to the line at which the squeegee 36 and the rotating drum 12 are in contact. Located at intervals along the pipe are the spray nozzles 42 which release the high pressure water in a line just above the line of contact between the squeegee 36 and drum 12.
The water spray helps release the oil from the drum 12, and, more specifically, it removes oil from the pores of the mesh 14. Removing the oil from the holes in the mesh 14 serves several purposes: it increases the amount of oil retrieved, allows the vacuum system 18 to work more effectively, and by preventing the mesh 14 from becoming clogged with oil, it allows water to easily pass through.
Once the oil has been removed from the drum 12 and is in the collection trough 38, it must be transported up to the ship to which the recovery system 10 is attached, where it will be stored. The oil removal system 22 comprises several Archimedean screws working in tandem. A geared motor (not shown) located on the ship turns a gear 44 which is connected to the first Archimedean screw 46, as in FIG. 7. As the motor runs, the gear 44 rotates causing the screw 46 to twist. The revolution of the screw 46 causes another gear 48 located at the opposite end of the screw 46 to turn, see FIG. 1. This gear 48 drives a worm gear 50 which is attached to another Archimedean screw 52. The rotation of the second screw 52 causes the oil in the collection trough 38 to be driven to one side of the trough 38. At the end of the trough 38, on the side to which the oil is being driven, is the beginning of the first screw 46, the rotation of which carries the oil up to the ship.
In the preferred embodiment the rotation of screws 46 and 52 is also responsible for driving the oil recovery drum 12. One end of screw 52 carries the worm gear 50 which is connected to the gear 48 of screw 46, and the other end of screw 52 carries a gear 54. When the oil removal system is in operation, the rotation of screw 52 will drive gear 54. Gear 54 will then engage chain 56, causing gear 58 to rotate. Gear 58 is attached to one of the endcaps of the drum 12, and thus, through gear 58 the drum 12 is caused to rotate. Adjustment screw 60 has been provided to alter the distance between gear 54 and gear 58, thus ensuring adequate tension in chain 56.
The particle deflection means 62 comprises oil direction wedges 64 connected on either end of a plurality of debris diversion tines 66. The deflection wedges 64 are used to divert more oil into the recovery system. They concentrate the oil into a smaller area so that the drum 12 can effectively remove it from the water. As shown best in FIG. 3, the debris diversion tines 66 of the preferred embodiment substantially define an S-shaped configuration in order to push any particle that is in danger of obstructing the system 10 under the rotating drum 12. This is a very important function for if debris were to enter the oil recovery system, damage could occur to the drum 14, the squeegee 36, or the Archimedean screws 46, 52.
A support system is provided to attach the recovery system 10 to the ship and to keep the components in place. The support structure comprises beams 70 and 78, shown in FIGS. 1 and 3, rails 74, illustrated in FIGS. 5 and 6, and roller 72, pictured in FIG. 6.
In FIG. 1, beams 78 are placed on either side of the drum 12. Located in the middle of each beam 78 is a pivotally mounted bar 82. This bar 82 can be locked with a pin 84 and is used to secure sleeve 34 in a fixed position relative to beam 84, as illustrated in FIG. 3. By fixing the position of sleeve 34, drum 12 is also secured in place since the sleeve 34 and drum 12 ar directly connected.
The particle deflection means 62 can be connected to the front ends of beams 78 and beams 70 attached to the back ends, as shown in FIG. 1. Further, the back end of each beam 70 is attached to a roller 72, illustrated in FIG. 5, whereby the roller 72 is confined to vertical motion by rails 74 on the ship, pictured in FIG. 6. The rollers 72 in combination with the beams 70 allow the apparatus limited vertical movement so that the system can tolerate wave motion. The level of movement has top and bottom restrictions, as defined by rails 74, to prevent the support beams 70 from becoming submerged or detached from the ship.
The level of buoyancy the system 10 possesses is important to its operation since the rotating drum 12 must float upon the surface of the water, and should not become mired in a slew of water, oil, and machinery. If the buoyancy provided by the support rods 26 in the drum should prove insufficient, the system 10 provides for buoyancy enhancement devices so, such as those shown in FIG. 2. These large hollow drum-like objects 80 can be bolted or otherwise attached to the forward section of beam 78 for additional buoyancy.
In the detailed description above, the configuration and operation of an improved oil recovery system was described. A rotating drum, whose surface is fabricated from stainless steel mesh, works in conjunction with a vacuum system to retrieve oil from a water surface. The combined efforts of a squeegee and a water spray system is required to remove the oil from the drum, which is subsequently moved to a storage facility. Archimedean screws are used to transport the oil and to drive the rotation of the steel drum, thus keeping the entire system working in tandem. The system requires a support structure to keep everything in place, and provides for additional buoyancy attachments if necessary.
While a preferred embodiment of an oil recovery system has been shown, it will be understood that there is no intent to limit the invention to such a disclosure, but rather it is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention as defined in the appended claims.
Having thus described the aforementioned invention, | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electric motor used for railway vehicles such as the electric car, and more particularly, it relates to an air-cooled type induction motor capable of taking air into the motor to cool the motor.
2. Description of the Related Art
Some of the air-cooled type motors are disclosed in a chapter titled "On The Induction Motor For Use With Vehicles" in the magazine "SCIENCE OF ELECTRIC CARS", February edition, 1988, pages 18-23, in published Unexamined Japanese Patent Application No. 61-94545, and also Utility Model Application No. 62-11371. As apparent from these references, the squirrel-cage type induction motor which can be controlled by VVVF inverters is now being used as the main motor for railway vehicles such as the electric train. The induction motor has no brushes. This enables the motor to require less maintenance, rotated at a higher speed, and made smaller in size, lighter in weight and larger in capacity.
The air-cooled squirrel-cage type induction motor includes a stator and a rotor. The stator includes stator core, coils and the like. The stator core is fixed to the inner circumference of the housing or frame of the motor. The stator coils are incorporated into inner circumferential portions of the stator core. Further, bearings for supporting the rotor in a smoothly rotatable state are arranged around the center of each of both end plates which form a part of the frame and which hold the rotor between them. The rotor includes a rotor shaft, a rotor core, a plurality of rotor bars, two end rings and the like. Both ends of the rotor shaft are supported rotatable by bearings The rotor core is fixed to the rotor shaft. The plurality of rotor bars are incorporated into the outer circumferential portion of the rotor core. Both ends of each of these rotor bars are connected to the end rings.
In the case of the air-cooled motor having the above-described structure, a moving magnetic field is generated from the stator coils when current is supplied to them. When this moving magnetic field crosses the rotor bars, an electromotive force is derived. The rotor is rotated by interaction between the current and magnetic field generated.
In the case of this air-cooled motor, a large amount of heat is generated from the stator and the rotor when the motor is being rotated. When the stator coils and the rotor bars are heated by this heat to temperatures higher than predetermined ones, the insulating capacity of the stator coils is deteriorated while the strength of material of which the rotor bars are made is lowered. In order to prevent this, outside air is taken into the motor to cool its inside when it is being rotated.
This air-cooled motor is provided with an air inlet port at one end thereof in the axial line around which the stator is rotated. Further, an air outlet port is formed at the other end of the motor. Furthermore, a gap is formed between the stator core and the rotor core, and a plurality of ventilating holes are formed in the rotor core in the rotor, extending along the axial line around which the rotor core is rotated.
The induction motors of this kind are grouped into the ones of the forcedly-cooling type in which cooling air is forcedly fed from outside into the frame through the air inlet port, using a fan located outside the motor, and the ones of the induced type in which an impeller fixed to the rotor shaft is located in the frame and rotated together with the rotor to take the cooling air into the frame through the air inlet port.
The cooling air introduced into the frame is taken into one end of the stator core and blown out of the other end thereof, passing through the plurality of ventilating holes. This cooling air is finally exhausted outside the frame through the air outlet. The stator coils, the rotor bars and the like in the frame are cooled by the cooling air which passes through the frame.
The above-described induction motor is provided with a plurality of narrow ventilating holes through which the cooling air is circulated. Sound waves (or noise) having an uncertain frequency are generated by the cooling air thus circulated. The frequency of the sound waves changes as the rotation number of the motor is increased (the vehicle is accelerated) or decreased (the vehicle is decelerated). This noise is harsh to the ears of the human being and it makes passengers in the vehicle feel uncomfortable. When the motor is used for railway trains, for example, the noise is feared to cause a public nuisance to those people who live along the railroad. Further, in the case where the noise is increased when the motor comes to or near to its usually-used rotation number, the vehicles cannot be practically run on roads or railroads.
SUMMARY OF THE INVENTION
An object of the present invention is therefore to provide an induction motor capable of keeping noise low while it is being rotated.
Another object of the present invention is to provide an induction motor smaller in size but larger in output capacity.
A further object of the present invention is to provide an induction motor sufficiently resistant to vibration.
According to the present invention, there can be provided an air-cooled type induction motor for use in vehicles comprising a cylindrical housing having an axis, an air inlet into which cooling air is supplied, and an air outlet which exhausts the cooling air, a stator for generating a magnetic field, the stator including an annular core coaxially fitted in the housing and located between the air inlet and the air outlet, and a plurality of stator coils having coil ends which extend from the core to the air outlet and which face to the inner circumferential surface of the housing with a space therebetween, a rotor coaxially arranged inside the core with a predetermined gap through which the cooling air flows from the air inlet to the air outlet and rotatable about the axis of the housing, the rotor having a shaft coaxial with the axis of the housing, a plurality of ventilating holes extending through the rotor along the shaft and through which the cooling air flows from the air inlet to the air outlet, and a plurality of rotor bars extending along the shaft and to which current is supplied, and a sound insulating means for directing the cooling air flowing into the air outlet in a desired direction so as to decrease sound waves generated by circulation of the cooling air, the sound insulating means being arranged in the space between the coil ends of the stator coil and the inner circumferential surface of the housing, and being separated from the coil ends by a certain distance which is shorter than half the wavelength length of the sound waves generated by the cooling air having such a frequency that depends upon the sum obtained by multiplying the number of the rotor bars by the rotation number of the rotor.
The noise which is generated by the circulation of air for cooling the induction motor and caused by the motor itself rotated at high speed can be thus eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a first example of the air-cooled induction motor according to the present invention sectioned along the rotor shaft of the induction motor and symmetrical relative to the axial line of the rotor shaft;
FIG. 1B is an enlarged partly-sectioned view showing a sound insulating plate and its adjacent area of the induction motor in FIG. 1A in more detail;
FIG. 2 is an enlarged partly-sectioned view showing a variation of the first air-cooled induction motor according to the present invention, in which a sound insulating plate and its adjacent area of the motor are shown in more detail;
FIG. 3A shows a part of a second example of the air-cooled induction motor according to the present invention sectioned along the rotor shaft of the motor and symmetrical relative to the axial line of the rotor shaft;
FIG. 3B shows a part of the second air-cooled inductor motor according to the present invention sectioned in a direction perpendicular to the rotor shaft of the motor;
FIG. 4 is a partly-sectioned view showing a variation of the second air-cooled inductor motor according to the present invention, in which the motor is sectioned in a direction perpendicular to its rotor shaft;
FIG. 5A shows a third example of the air-cooled induction motor according to the present invention sectioned along the rotor shaft of the motor and symmetrical relative to the axial line of the rotor shaft;
FIG. 5B shows a part of the induction motor in FIG. 5A sectioned in a direction perpendicular to the rotor shaft of the motor;
FIG. 5C is an enlarged partly-sectioned view intended to explain how noises can be reduced by the third air-cooled induction motor shown in FIGS. 5A and 5B;
FIG. 6A shows a part of a variation of the third air-cooled induction motor sectioned along the rotor shaft of the motor and symmetrical relative to the axial line of the rotor shaft; and
FIG. 6B shows a part of the induction motor in FIG. 6A sectioned in a direction perpendicular to the rotor shaft of the motor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1A and 1B show a first example of the air-cooled squirrel-cage type induction motor according to the present invention. The squirrel-cage type induction motor 2 includes a cylindrical motor housing or frame 4 into which a stator 10 for generating a magnetic field is shrinkage-fitted and which is provided with a squirrel-cage type rotor 30 rotatably supported inside the stator 10. The stator 10 has stator coils 12 to which current is supplied to generate the magnetic field, and stator core 14 for supporting the stator coils 12. The cylindrical frame 4 has an air inlet port 4a, an end plate 6 at its one open end and another end plate 8 having an air outlet port 8a at its other open end along its axial line around which the rotor 30 is rotated. The stator core 14 is formed by stacking a large number of thin iron plates 16 one upon the other to each of which insulating matter is laminated. The stator core 14 is fixed to the inner circumference of the frame 4 by means of holder members 18. A plurality of slots 20, parallel to the shaft of the frame 4, are formed in the inner circumferential portion of the stator core 14. The stator coils 12 are incorporated into the slots 20 in the stator core 14. The stator coil 12 directs its one end 22 in a direction parallel to the axial direction in which the stator core 14 is rotated and its another end 24 in a direction reverse to that direction in which the one end 22 of the stator coil 12 is directed. Bearings 26 and 28 are located at center portions of the end plates 6 and 8 of the frame 4.
The squirrel-cage type rotor 30 includes a rotor or motor shaft 32 passing through its center, a rotor core 34 provided with a plurality of rotor bars 36 each formed by a copper band and arranged at a same interval, and two rotor holder members 38 for sandwiching the rotor core 34 between them. The rotor shaft 32 is smoothly rotatably supported by the bearings 26 and 28 located at the center portions of the end plates 6 and 8. The rotor core 34 is formed by stacking a large number of thin iron plates 40 one upon the other to each of which insulating matter is laminated. The rotor core 34 is fixed to the rotor shaft 32 by the holder members 38. A plurality of slots 44 are formed in the outer circumferential portion of the rotor core 34. The rotor bars 36 are incorporated into the slots 44 of the rotor core 34. One end of each of the rotor bars 36 is directed in a direction parallel to the axial direction in which the rotor core 34 is rotated while the other end thereof in a direction reverse to that direction in which the one end of the rotor bar 36 is directed. Both ends of each of the rotor bars 36 are connected to each other by short-circuit or end rings 46. A gap G is formed between the outer circumference of the rotor core 34 and the inner circumference of the stator core 14. A plurality of ventilating holes 48 extend along the axial line around which the rotor core 34 and its holder members 38 are rotated, passing through the rotor core 34 and its holder members 38.
The air-cooled induction motor 2 further includes, between the frame 4 and the stator coils 12, a sound insulating plate 50 for preventing sound waves from being amplified. The sound insulating plate 50 is made of a metallic or non-metallic material and formed like a ring, extending along the outer circumference of the stator coils 12 and in the circumferential direction of the frame 4. The sound insulating plate 50 has at one end thereof a flange 52, which is fitted into the inner circumference of the stator core holder member 18 and fixed between the frame 4 and the stator coils 12 by pressing the holder member 18 against one end face of the stator core 14. The sound insulating plate 50 is tapered, spreading more and more as it comes from its one end at which the flange 52 is formed nearer to its other open end 54, and it serves as a centrifugal fan for exhausting high pressure pulsating air current K, which is blown out of slit-shaped clearances at the stator coils 12, outside through its open end 54 as exhausted air current L when the rotor bars 36 are rotated at high speed.
It will be now studied how sound waves (or noise) S having a specific frequency are generated in the induction motor.
The both ends of each of the rotor bars 36 are projected from the both ends of the rotor core 34. When the rotor 30 is rotated, therefore, cooling wind H is sucked through the air inlet port 4a into the motor 2 and circulates toward the air outlet port 8a to generate wind I which has relatively high pressure. The high pressure wind I blows through the motor 2, as if it were a centrifugal fan, from the center of the rotor 30 or rotor shaft 32 in a direction or radial direction perpendicular to the shaft 32. Each of the rotor bars 36 has a relatively large thickness to create a sectional area necessary enough to serve as a copper conductor. It is therefore well-known that the high pressure wind I becomes pulsating air current J whose maximum value changes as time changes. It is also well-known that the vibration v or frequency f of the pulsating air current J depends upon that product which is obtained by multiplying the number of the rotor bars 36 by the rotation number of the rotor 30. The stator coil 12, its copper wire occupying a large ratio of its sectional area, being curved to enter into a next slot and formed like a circumference in the stator 10, serves to exhaust the pulsating air current J, which is discharged through the rotor 30, in the outer circumferential direction of the motor 2 as high pressure pulsating air current K. The high pressure pulsating air current K is rapidly diffused in a hollow formed outside the stator coils 12 to generate sound wave S which cause noise. The high pressure pulsating air current K or sound waves is reflected by the inner wall of the frame 4 and again returned back to those portions of the stator coils 12 where the high pressure pulsating air current K is exhausted. The high pressure pulsating air current K thus returned is again directed toward the frame 4 together with its following high pressure pulsating air current K and then reflected by the frame 4. The high pressure pulsating air current K is therefore reciprocated between the inner wall of the frame 4 and the outer circumferential portions of the stator coils 12. The inner wall of the frame 4 and the outer circumferential portions of the stator coils 12 cooperate this time to serve as if they were a resonance box. The sound waves (or noise) which is S generated by the high pressure pulsating air current K is thus gradually amplified to become noise uncomfortable to the ears of the human being. It has been confirmed by tests that this amplifying of the sound waves S is increased particularly at the time when the distance l of the inner wall of the frame 4 relative to the outer circumferential portion of the stator coils 12 is about 0.5 or 1 times the wavelength λ of the sound waves S. The pulsating air current J, high pressure pulsating air current K and sound waves S cannot be distinguished from one another. Therefore, they are denoted by J(K) or K(S), for example, in the accompanying drawings).
The position of the sound insulating plate 50 to be located or the distance of the sound insulating plate 50 relative to the outer face of the stator coils 1 will now be studied. As described above, the sound waves (or noise) S is generated by the pulsating air current K and its frequency is defined by the product obtained by multiplying the number of the rotor bars 36 by the rotation number of the rotor 30. The frequency f of the sound waves S which are feared to become noise is therefore defined as follows: Assuming that the number of the rotor bars 36 is 26 (smallest in the case of the now-available induction motors) and that the rotation number of the rotor 30 is 3000 r.p.m. (smallest of those rotation numbers of the induction motor which make the human being hear noise),
f.sub.L =26×3000/60=1300Hz
Assuming that the number of the rotor bars 36 is 46 (common in the now-available inductor motors) and that the rotation number of the rotor 30 is 7000 r.p.m. (largest in the now-available induction motors),
f.sub.U =46×7000/60=536Hz
The most popular speed range in which the induction motor 2 is rotated is obtained when the rotor 30 is rotated at a speed of 5000 r.p.m. When the number of the rotor bars 36 is 46, therefore,
f.sub.N =46×5000/60=3833Hz
(subscripts L, U and N annexed in the above-cited equations denote the smallest rotation number of the rotor 30 which make the human being hear noise, the largest rotation number of the motor, and the most popular speed range in which the motor is rotated).
On the other hand, it has been confirmed by tests that the amplifying of the sound waves S is increased to the greatest extent particularly at the time when the distance l between the inner wall of the frame 4 and the outer circumferential portion of the stator coils 12 is about 0.5 or 1 times the wavelength λ of the sound waves S. It is therefore preferable that the sound insulating plate 50 is located at a position where the distance l between the inner wall of the frame 4 and the outer circumferential portion of the stator coils 12 becomes smaller than 0.5 times or larger than 1 time the wavelength λ of the sound waves S. In other words, the sound insulating plate 50 is located at a position where a distance l 1 measured from the outer face of the stator coils 12 is considerably smaller than half the wavelength λ of the sound waves S which has the frequency f. (Numerals 1, 2 and 3 annexed in the following represent the first, second and third examples of the induction motor 2 according to the present invention).
Wavelength λ L of the lowest frequency f L relating to the sound waves S which are feared to become noise is as follows:
λ.sub.L =330000(mm/sec)/1300(1/sec)=254mm
Therefore, distance l 1L of the sound insulating plate 50 relative to the outer face of the stator coils 12 is preferably as follows:
254×0.5=127mm>l.sub.1l
Wavelength λ N of frequency f N relating to the sound waves S which is created at the time when the motor are normally operated is as follows:
λ.sub.N =330000(mm/sec)/3833(1/sec)=86.1mm
Therefore, distance l 1N of the sound insulating plate 50 relative to the outer face of the stator coils 12 is more preferably defined as follows:
86.1×0.5=43mm>l.sub.1n
In addition, wavelength λ U of the highest frequency f U relating to the sound waves which are created at the time when the rotation number of the rotor 30 is the largest is calculated as follows:
λ.sub.U =330000(mm/sec)/5367(1/sec)=61.5mm
Therefore, distance l 1U of the sound insulating plate 50 relative to the outer face of the stator coils 12 is gained as follows:
61.5×0.5=30mm>l.sub.1u
However, the distance l 1L of the sound insulating plate 50 relative to the outer face of the stator coil 12 when the frequency is the lowest f L becomes about 2 times the distance l 1U of the sound insulating plate 50 and it is therefore feared that the noise S is increased at the time when the speed of the motor is in the low speed range. Therefore, the distance l 1 of the sound insulating plate 50 relative to the outer face of the stator coils 12 is practically defined in such a way that the sound insulating plate 50 can function most effectively at the frequency f N of the sound waves S which are generated at the time when the motor is normally operated. When the distance l 1 becomes too short, it is feared that the sound insulating plate 50 prevents cooling or high pressure wind H, which serves to cool the motor 2, from easily passing through the motor 2. The distance l 1 of the sound insulating plate 50 relative to the outer face of the stator coil 12 must be therefore kept longer than at least 10 mm. It has been confirmed by results of various tests that the distance l 1 is the optimum when it is in a range of 20-35 mm.
This sound insulating plate 50 can prevent the sound waves S, which are generated when the rotor 30 is rotated, from being amplified. More specifically, when the rotor bars 36 are rotated and the high pressure pulsating air current K is thus generated, the air current K is introduced to the sound insulating plate 50, passing between the stator coils 12. This high pressure pulsating air current K is reflected by the sound insulating plate 50 which is separated from the outer face of the stator coils 12 by the distance l 1 . It is thus made different in phase from its following high pressure pulsating air currents which will be successively generated. When this pulsating air current K whose phase has been changed is struck against its following pulsating air current, the sound waves S can be prevented from being amplified.
The sound insulating plate 50 is tapered, spreading more and more from its flange 52 to its open end 54, and this enables the pulsating air current K to be more quickly exhausted from the air outlet port 8a, as exhausted current L, along the tapered portion of the sound insulating plate 50.
The space between the stator coils 12 and the frame 4 is made narrower by the sound insulating plate 50 than in the case of the conventional motors. When the pulsating air current K is to be exhausted outside as the exhausted current L, it passes through an inner of stator coils 12 to thereby cool the motor 2 to a greater extent.
FIG. 2 shows a variation of the sound insulating plate shown in FIGS. 1A and 1B. The same components as those in FIGS. 1A and 1B will be represented by the same reference numerals. According to this variation of the sound insulating plate, it is formed integral to one of the holder members or stator core holder members 60 which serve to fix the stator core 14 to the inner circumference of the frame 4. The core holder member 60 presses the stator core 14 inward by its one end while it allows the high pressure wind I blown through the gap G to be exhausted at an interval of the predetermined distance l 1 . That end 62 of the core holder member 60 which is located opposite to the stator core 14 is bent to contact with and fix to the frame 4. Even when the rotor shaft 32 or rotor bars 36 rotates or the induction motor 2 vibrates, therefore, a rigid sound insulating plate which neither vibrates nor contacts the rotor 30 can be provided.
FIGS. 3A and 3B show a second example of the aircooled squirrel-cage type induction motor according to the present invention. The same components as those in FIGS. 1A and 1B will be denoted by the same reference numerals.
According to this second example, sound wave induction plates 70 each being formed by a plurality of thin plates, having a relatively long length l 2 when it is developed, and serving to extinguish the sound waves (or noise) S generated by the rotating rotor 30, are arranged in a space defined by the stator coils 12 and the rotor 30 in the frame 4. The sound wave induction plates 70 are supported, directing in a same direction, by induction plate bosses 72, each of which is fixed to one of the stator holder members 18 at one end thereof, and they are assembled as a part of the frame 4 or integral to the frame 4 because their bosses 72 are fixed to the frame 4. That end of the sound wave induction plates 70, which are located opposite to its end fixed to the stator holder member 18, is provided with a stopper 74 for preventing each of the sound wave induction plates 70 to contact the others while vibrating. The sound wave induction plates 70 are incorporated into the induction plate bosses 72 and the stopper 74 which are two- or four-divided in a direction perpendicular to the rotor shaft 32. The sound wave induction plates 70 are arranged enclosing the rotor shaft 32 because the induction plate bosses 72 and the stoppers 74, each of which is two- or four-divided, are fixed to the frame 4 in the circumferential direction of the frame 4.
As already described above, the high pressure wind I is generated by the rotating rotor bars 36. The pulsating air current K is caused by the high pressure wind I which passes through the stator coils 12. The pulsating air current K is introduced into cooling wind passages 76 formed by the sound wave induction plates 70, guided along the curved passages 76 and discharged, as the discharged air current L, into the gap G between the frame 4 and the sound wave induction plates 70. However, a part of the pulsating air current K is reflected by the inner circumference of the frame 4 and is again introduced to the rotor shaft 32. When each of the passages 76 and the gap G are sufficiently large (or wide) in this case, it is well known that the sound waves (or noise) S kill one another to become reduced to a greater extent because the pressure of the pulsating air current K (or sound waves S) is reduced or pressure directed in the reverse direction is generated. When the passages 76 and the gap G are not large (or wide) enough or none of the passages 76 and the gap G are present, the pulsating air current K (or sound waves S which are uncomfortable to the ears of the human being) is introduced, as it is, to the rotor shaft 32.
Because the sound wave induction plates 70 is shaped like a spiral, the passages 76 and the gap G can be kept sufficiently large or wide. As already described above, the distance l between the inner wall of the frame 4 and the outer circumference portion of the stator coils 12 which are feared to form a resonance box can be made sufficiently long relative to the wavelength of the sound waves S which are suspected to originate noise. The amplifying of the sound waves S is increased particularly when the distance becomes about 0.5 or 1 times the wavelength λ of the sound waves S. The distance l 2 is therefore made sufficiently larger than 1 time the wavelength of the sound waves S which has such frequency that causes noise. This prevents the pulsating air current K (or sound waves S), which has been reflected by the inner wall of the frame 4, from being amplified and the occurrence of the noise S which is uncomfortable to the ears of the human being can be thus prevented.
When the passages 76 and the gap G are made sufficiently large (or wide), it is feared that the pulsating air current K (or sound waves S) is amplified at the time when the motor 2 is rotated at a relatively low speed. When the motor 2 is rotated at a relatively low speed, however, the pressure of the pulsating air current K itself which causes such sound waves that are heard as noise to the ears of the human being becomes relatively small. The time during which the motor 2 is rotated at low speed corresponds to those time periods during which the vehicle is accelerated and decelerated, and these time periods occupy only a little part of that time during which the vehicle is being driven. It hardly happens therefore that the human being feels the sound waves as noise.
FIG. 4 shows a variation of the sound wave induction plates. According to this variation, sound insulating plates 80 are shaped like a reversed L (it may be expressed that the plates 80 are shaped like a L depending upon the direction in which their section is viewed) when they are sectioned in a direction perpendicular to the rotor shaft 32. In these sound insulating plates 80, the distance l 2 can be made sufficiently long relative to the wavelength λ of the sound waves S which are feared to originate noise.
FIGS. 5A and 5B show a third example of the air-cooled squirrel-cage type induction motor according to the present invention. The same components as those in FIGS. 1A and 1B will be denoted by the same reference numerals.
According to this third example, sound wave induction blocks 90 which serve to extinguish the sound waves (or noise) S generated by the rotating rotor 30 are formed in the space between the stator coils 12 and the frame 4. Each of the sound wave induction blocks 90 is formed by piling plural cylindrical or polygonal hollow pipes in a plurality of layers in a direction perpendicular to the rotor bar 36 (or in the circumferential direction of the motor 2), and their lengths l 92 , l 94 , l 96 and l 98 are different for every layer (numerals 92, 94, and 98 annexed denote the layers of the pipes).
According to this sound wave induction blocks 90, the cooling wind I or high pressure pulsating air current K blown from the rotor 30 to the stator 10 is introduced into the pipes in the layers 92, 94, 96 and of the blocks 90. The pipes in one layer are different in length from those in the other layers. Therefore, the pulsating air current K is exhausted as the exhausted air current L after it is divided by the pipes in the layers 92, 94, 96 and 98, and its time needed to pass through them is changed by them. As apparent from FIG. 5C, the pulsating air current K which has passed through the pipes in the layers 92-98 is exhausted under the state that it is dispersed. The distance between the inner wall of the frame 4 and the outer circumferential portion of the stator coils 12 which serves to act as the resonance box can be thus changed at random relative to the wavelength of the sound waves S which are supposed to generate noise. In other words, the amplifying of the sound waves S comes to its peak particularly at the time when the distance l is about 0.5 or 1 times the wavelength λ of the sound waves S. When the lengths of the pipes in the layers 92-98 are made shorter than 0.5 times and/or longer than 1 time the wavelength λ of the sound waves S, therefore, the noise S which is uncomfortable to the ears of the human being can be prevented from being caused.
FIG. 6A and 6B show a variation of the third example according to the present invention. Each of sound insulating blocks 100 includes a plurality of sound insulating plates 102, 104, 106 and 108 having lengths l 102 (not seen in FIG. 6B), l 104 , l 106 and l 108 which are different in a direction perpendicular to the rotor bar 36 (or in the circumferential direction of the frame 4), and also having widths W102, W104, W106 and W108 which are different in a direction parallel to the rotor bar 36 (or in the axial direction of the frame 4). The cooling wind I or high pressure pulsating air current K blown from the rotor 30 to the stator 10 is introduced to the sound insulating plates 102-108 which have different lengths and widths and whose lengths and widths are made shorter than 0.5 times and/or longer than 1 time the wavelength λ of the sound waves S generated by the pulsating air current. The high pressure pulsating air current K introduced to the sound insulating plates 102-108 is exhausted to different positions both in the circumferential and axial directions of the motor 2. This prevents the pulsating air current K (or sound waves S) from being amplified, so that the occurrence of the noise S which is uncomfortable to the ears of the human being can be prevented. | 4y
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FIELD OF THE INVENTION
The invention relates to a coating apparatus and method or to a feed for a coating apparatus and method. More particularly, the invention concerns the creation of a free-falling curtain of a single coating composition that is highly uniform in flow rate for application to a moving surface or web.
BACKGROUND OF THE INVENTION
A common way to apply coatings to moving surfaces is to create a free-falling curtain of coating composition and to pass the surface to be coated through the curtain. FIG. 1 a, b and c show examples of curtain coating means of the prior art. In some applications, such as the painting of objects, the uniformity of the coating is not critical. In such cases, simple and inexpensive means known in the art can be used to form the curtain. For example, a weir can be used. The weir can be a basin having a relatively low edge along which the coating composition overflows to form a curtain. The coating composition is pumped or poured into the basin. If the overflowing edge is horizontal, and if the basin is wide and deep, a uniform curtain is created.
However, a large basin can have disadvantages. The size required to ensure a uniform curtain may exceed available space. A large basin may require thick walls or a sturdy platform to prevent mechanical sagging due to weight. In some operations, it may not be practical to recover the coating composition remaining in the basin at the completion of a production run; in this case, the larger the volume of the basin, the greater the loss of possibly expensive coating composition. A large basin also has regions where the coating composition is nearly stagnant. Gravitationally induced inhomogeneities of the coating composition can occur in stagnant regions if the coating composition is a dispersion or suspension of one phase in another of a different density; examples include silver grains in aqueous gelatin and matte particles in a liquid. A large basin is also subject to eddies or regions of flow recirculation. Stagnation zones where recirculations meet are particularly susceptible to gravitationally induced inhomogeneities. Inhomogeneities in the coating composition can produce visual or functional nonuniformities in the coating such as streaks.
However, reducing the volume of the basin while maintaining widthwise uniformity entails difficulties. As the cross section of the basin becomes smaller, the hydrodynamic resistance to flow in the direction of the width of the curtain increases; gravitational leveling may become incomplete, and where the level is higher, the curtain will have a higher flow rate. Similarly, the disturbing effects of the incoming liquid may not completely dissipate before the curtain forms in a basin of small cross section. One such disturbance is the jetting of the coating composition into the basin when it is introduced through a conduit or poured from a nozzle.
The following U.S. Pat. Nos. describe coating apparatus useful in curtain coating: 2,745,419; 3,067,060; 3,074,374; 3,205,089; 3,345,972; 3,365,325; 3,632,374; 3,717,121; 3,876,465; 4,060,649; 4,075,976; 4,230,743; 4,384,015; 4,427,722; 5,298,288.
Ways are known in the art to preserve flow uniformity while reducing the cross section of the distributor. One way, shown in FIG. 1a, is to feed the basin from a conduit with numerous holes spanning the coating width; however, the multiple, discrete streams promote areas of recirculation and stagnation in the basin. Another way, shown in FIG. 1b, is to employ an extrusion die having a distribution cavity and narrow slot through which the liquid is forced. If the flow resistance over the length of the slot is large compared to that over the length of the cavity, the liquid is distributed across the die. In the most demanding applications, two or more cavity/slot combinations are employed in series. The effectiveness of the die also depends on the rheological properties of the coating composition. The narrow slot of the die subjects a non-Newtonian coating composition to high rates of shearing where pseudoplasticity or viscoelasticity become complicating performance factors. So, a different die may be required for each product, or a means of adjusting the die geometry may be required, such as tailoring the height of the slot by applying an adjustable mechanical loading. Major disadvantages of an extrusion die are its mechanical complexity, tight fabrication tolerances, and resulting high cost.
FIG. 1a of the drawings is a weir for forming a curtain according to prior art (Method and Apparatus for Flow Coating Objects, J. Kinzelman, U.S. Pat. No. 3,205,089 issued Sep. 7, 1965). The weir consists of a single channel. Coating composition is delivered to a conduit running through the channel. The conduit has a series of holes along its length to feed the coating composition to the channel.
FIG. 1b is a die forming a curtain according to prior art (Coating a Heat Curable Liquid Dielectric on a Substrate, Curry, II et al; U.S. Pat. 5,298,288 issued Mar. 29, 1994). Inside the die is at least one distribution cavity connected to the inlet and spanning the width of the curtain. The curtain is extruded from a narrow slot adjoining the distribution cavity and spanning the width of the curtain.
FIG. 1c in the drawings shows another weir for forming a curtain according to prior art (Paint Curtain Machine and Method of Painting, J. H. Coleman, U.S. Pat. No. 4,060,649, Nov. 29, 1977). In this case the weir is simply a large basin.
SUMMARY OF THE INVENTION
The invention provides an inexpensive and versatile apparatus for creating a highly uniform curtain of a single coating composition for the purpose of coating surfaces. In particular, the invention achieves low holdup volume, flow patterns resistant to gravitationally induced coating nonuniformities, and insensitivity to the rheology of the coating composition.
By holdup volume is meant the volume of liquid contained within the curtain-forming apparatus, i.e. the basin (two-channel weir). When a coating is terminated, the weir contains this volume of coating composition. The coating composition cannot always be recycled, and so the holdup volume is potential waste. If the coating composition is solvent based and its vapors in air potentially explosive or toxic, the weir should be drained quickly. For these and other reasons mentioned in the specification, it is desirable to minimize the holdup volume.
Accordingly, an object of the invention is to provide an inexpensive method and apparatus for creating a highly uniform curtain of a single coating composition for the purpose of coating surfaces without the large volume and stagnant or recirculating flow patterns of the simple weir or the expense and complexity of the extrusion die. In particular, the invention achieves at low cost a small holdup volume and short residence time. It is a further object of the invention to provide a simple, inexpensive, and rapid way to accommodate different flow conditions and fluid properties. Further objects and advantages of the invention will become apparent from a consideration of the drawings and ensuing descriptions.
The invention consists of a basin divided into two channels by a wall spanning the coating width. Liquid is supplied to the primary channel, the channel farther from the curtain. The dividing wall is gapped to the bottom of the basin to pass the liquid from the primary to the secondary channel while providing some resistance to flow. The gap can be on the order of 0.1 inch and is several times larger than that used for extrusion dies. As a result, the shear rate to which the coating composition is subject is relatively low and non-Newtonian effects are minimized. In alternative embodiments, the dividing wall is perforated or porous instead of gapped from the bottom of the basin. The secondary channel has an edge configured as a pouring lip that is horizontal and relatively low so that the coating composition overflows it to form a free-falling curtain. The basin should overflow only at the lip where the free falling curtain forms. The side and back walls of the basin should have top edges higher than the lip to contain the liquid. Similarly, the top edge of the dividing plate should be high enough to contain the liquid during normal operation but low enough to overflow before the side and back walls in case of accidental flooding. The flow resistance created by the dividing wall is typically such that the drop in the level of the coating composition across the dividing wall is on the order of one centimeter. The flow resistance created by the dividing wall assists in distributing the supplied coating composition over the width of the curtain channel and diminishes any flow disturbances associated with the entering coating composition. The secondary channel promotes additional evening of the flow distribution before the curtain forms. A highly uniform flow distribution is indicated by a substantially level surface of the liquid in the secondary channel.
Preferably, the coating composition is supplied through a conduit feeding the center of the primary channel. In a preferred embodiment of the invention, an inlet is provided inside the primary channel to break up the jet from the conduit and direct the liquid toward the ends of the primary channel. The inlet also ensures that the velocity of the liquid is nearly constant over the cross section of the primary channel so that regions of stagnation and recirculation are avoided. The high, uniform velocity of the liquid from the inlet propels the coating composition to the cavity ends and so promotes a uniform flow distribution.
More preferably, the coating composition is supplied to the center of the primary channel through a conduit. A centrally located feed minimizes the distance over which the coating composition is distributed and creates a symmetry favoring the effectiveness of the secondary channel at evening the flow distribution; any variation in flow rate entering the secondary channel is symmetric about the center and evening the distribution requires flow over just half of the coating width. In the preferred embodiment of the invention, an inlet is added to the primary channel to break up jetting from the supply conduit and direct the liquid towards the ends of the primary channel. The inlet propels the coating composition to the ends of the weir. The initial kinetic energy greatly reduces the gravitational head that would otherwise be expended in driving the flow down the channel. A nearly constant depth in the primary channel promotes uniform flow into the secondary channel. The inlet also ensures that the velocity of the liquid is nearly constant over the cross section of the primary channel so that regions of stagnation and recirculation are avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a, 1b, and 1c shows the creation of the curtain using weir and die means of the prior art.
FIG. 2 is a schematic, three-dimensional view of the weir apparatus of the invention.
FIG. 3 is a vertical cross section through the weir showing the dividing wall.
FIG. 4 is a vertical section through the dividing wall showing the continuous gap between the dividing wall and the bottom of the basin.
FIG. 5 shows a dividing wall of perforated plate.
FIG. 6 shows a dividing wall shaped so as to reduce flow stagnation and recirculation in the secondary channel.
FIG. 7 shows a view of the inlet from above.
FIG. 8 shows enlarged views of the inlet from above (a), from the side (b), and from the front (c).
FIG. 9 shows the drop in velocity in the primary channel when the cross section is uniform.
FIG. 10 shows the uniform velocity in the primary channel when the cross section is linearly tapered.
FIG. 11 shows the dimensions of the cross section of the weir of the Example.
For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following detailed description and appended claims in connection with the preceding drawings and description of some aspects of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of the invention for forming a uniform curtain for application to a receiving surface is shown in FIG. 2. The apparatus consists of a basin 10 divided into a primary channel 11 and a secondary channel 12 by dividing plate 13. The basin has two end caps 14 that determine its lateral extent. Replaceable endcaps of various lateral dimension may be used to change the width of the coating. The basin has an inlet end 15 where coating composition is supplied to the primary channel. The inlet has the following essential elements:
a) a port to receive the coating composition from the conduit. The supply conduit should be in a vertical plane that is perpendicular to the curtain at the center of the width of the curtain;
b) the inlet itself is an enclosure (box) centered on this port and filling the cross section of the primary channel from the backwall of the basin to the dividing plate. The top, bottom, front and back sides of the inlet enclosure are solid. The sides of the inlet enclosure consist of one or more layers of perforated plate lying in vertical planes perpendicular to the curtain. Coating composition exits the sidewalls in the direction of the axis of the channel and is distributed evenly over the cross section of the channel;
c) preferably, the outermost perforated plate of the sidewall is corrugated so that the open area of this plate is at least 50% of the cross-sectional area of the primary channel. The corrugations are symmetric about lines and planes parallel to the axis of the channel such that components of lateral flow (flow perpendicular to the axis of the channel) from the corrugations cancel one another.
d) optionally, the front plate of the inlet enclosure is gapped from the dividing wall and perforated.
In FIG. 2, coating composition is supplied through a conduit 16 to the center of the primary channel. An inlet 25 within the primary channel directs the liquid along the axis of the primary channel. The coating composition flows along the primary channel towards the end caps 14 because of its momentum in that direction from the inlet and because of gravitational leveling. When the momentum is significant, little or no drop in liquid level occurs from the center to the ends of the primary channel. A nearly uniform level in the primary channel favors uniform flow into the secondary channel.
There are other, less advantageous ways in which the primary channel can be supplied with coating composition. A supply conduit can be located at other lateral positions or at an end of a channel, and multiple supply conduits can be distributed widthwise. The supply conduit can run through the primary channel from end cap to end cap and supply coating composition through numerous holes. The coating composition can be poured into the primary channel at one or more positions.
The dividing wall 13 creates a resistance to flow from the primary channel to the secondary channel. This resistance promotes the distribution of the coating composition along the primary channel and diminishes any disturbances associated with the entry of the coating composition. The dividing wall is a critical element of the invention, and it is described in detail below.
As shown in FIG. 3, the coating composition entering the secondary channel 12 from the primary channel 11 flows primarily across the secondary channel to an outlet end 17 of basin 10. The outlet end 17 is configured as a horizontal pouring lip that the coating composition overflows to form a free falling curtain 18. The overflow may simply take place over a horizontal edge of the basin. Preferably, however, the outlet end of the basin is a lip 19 contoured to direct the coating composition vertically downward. Lip configurations conducive to forming a free falling curtain are known in the art; for example, U.S. Pat. Nos. 5,462,598 and 5,399,385. The pouring edge or lip must be lower in elevation than the end caps, the back wall of the basin, and the dividing wall so that the coating composition overflows only there. The pouring edge or lip should be accurately horizontal to promote a uniform curtain.
It is well known in the art that if the edges of a free-falling curtain are not supported by vertical edge guides, the curtain narrows as it falls because surface tension causes the edges of the curtain to roll up. Edge guides 20 can be employed to support surface tension and maintain the width of the free-falling curtain. In some applications, particularly when the curtain is wider than the receiving surface, the narrowing of the curtain is not objectionable. In most cases, however, maintaining the width of the curtain is desirable, and the edge guides known in the art can be used; for example, U.S. Pat. Nos. 4,830,887, 5,328,726, and 5,395,660.
Curtain height can vary from a few to several tens of centimeters. Generally, higher curtains promote increased coating speed without the entrainment of air between the coating and the receiving surface. For high flow rates or low viscosities, the receiving surface is advantageously tilted forward to preclude the formation of a puddle at the line of impingement. In FIG. 2 the receiving surface for the coating 21 is a web 22 conveyed through the curtain by a backing roller 23, but many other receiving surfaces are possible. As another example, the receiving surface may consist of discrete objects on a conveyor belt. The receiving surface may also be the surface of a roller used to supply a roll coating process with coating composition, or a gravure cylinder that is subsequently bladed and contacted with a web.
The dividing wall allows coating composition to pass from the primary to the secondary channel while providing some resistance. Resistance is indicated by a drop in the elevation of the surface of the coating composition between the primary and secondary channels. Preferably, as shown in FIGS. 3 and 4, there is a continuous gap 24 between the dividing wall 13 and the basin 10. The length and height of this gap determines the flow resistance. In the examples, the gap is 0.11 inches. The gap depends upon the flow rate and the properties of the coating composition. In practice, the gap is reduced until the level of the surface in the primary channel is higher than the level in the secondary channel by a distance of the order of a centimeter. The gap is readily altered by raising or lowering the dividing wall by its ends. Besides the ease in adjusting flow resistance, the gapped dividing wall precludes the regions of stagnation and flow recirculation caused by a discontinuous flow path. The gapped dividing wall also helps to exclude large air bubbles from the coating. To reach the curtain, bubbles must be drawn under the dividing wall against their buoyancy.
The gapped dividing wall also provides the option of varying the flow resistance across the width of the coating. The bottom of the wall may be contoured so that the gap varies along the length of the channels as desired, as shown in FIG. 4. Alternatively, the thickness of the wall may be contoured. The gap can also be altered by applying an adjustable mechanical load to the dividing wall so that it bends. Reasonable mechanical loads can be achieved through choice of construction material, or by designing the wall to weaken it structurally.
Although a continuous gap is preferred, the dividing wall 13 might alternatively be made of perforated or drilled plate, as shown in FIG. 5. The holes can have any cross sectional shape although a circular shape is most common. Flow resistance is controlled primarily by the open area of such plates. A wall that is porous is the extreme of a wall with perforations. A perforated wall can be effective at laminarizing the flow and promoting a smooth curtain; large turbulent eddies are broken down into smaller eddies that rapidly dissipate. However, walls with multiple passageways can create a three-dimensional flow field that is conducive to regions of stagnation and recirculation. Part or all of the dividing wall may be perforated. The wall is perforated by drilling or punching, and most commonly the cross section of a perforation is circular. The diameter of the perforations should be small enough to provide flow resistance but large compared to any particulates dispersed in the coating composition and large enough for the drilling and punching operation; for example, a suitable diameter may be about 0.1 inch. The size and spacing of the holes is determined so that, for the desired coating composition and flow rate, the level of the surface of the liquid in the primary channel is higher than the level in the secondary channel by a distance on the order of a centimeter.
In a preferred embodiment, the basin and dividing wall can be contoured to reduce regions of stagnation and recirculation in the secondary channel. The dividing wall is preferably of cylindrical shape (the surface is traced by a straight line moving parallel to a fixed straight line and intersecting a fixed planar closed curve). As FIG. 3 shows, the wall of the basin at the outflow end 17 is preferably angled upward from the dividing wall to avoid a corner. As an additional measure, the dividing wall can be shaped so as to reduce the angle at which the flow expands in the secondary channel, as shown in FIG. 6. The smaller the angle of divergence of the flow, the less likely flow recirculations will be encountered. As is well known in hydrodynamics, the larger the Reynolds number, the more likely flow separation and turbulence will occur. The preferred Reynolds number for the coating composition is between 0.1 and 10.
As a safety feature, it is preferred that the height of the edges of the basin, except for the edge where the liquid overflows to form the curtain, exceed the elevation of the top surface of the dividing wall. Then, should the resistance of the dividing wall be too high, as by incorrect setting of the gap, or should the flow rate supplied surge for whatever reason, the liquid will overflow only the dividing wall and remain confined to the basin.
In a preferred embodiment of the invention, the primary channel has a centrally located inlet 25 that receives the incoming coating composition and directs it along the length of the primary channel. To avoid areas of stagnation and recirculation, the velocity from the inlet should be nearly uniform over the cross section, as FIG. 7 suggests.
A central location for the inlet is preferred because this minimizes the distance over which the coating composition flows. Gravitational leveling of the liquid in the primary channel promotes a uniform distribution over the width of the coating. However, the differences in depth that drives the liquid along the primary channel, the variation in the so called gravitational head, also drives liquid into the secondary channel through the flow resistance of the dividing wall. Thus, minimizing the depth variation in the primary channel is advantageous. A way to accomplish this consistent with the object of minimizing the volume of liquid in the basin is to create an inlet that propels the liquid towards the end caps 14 of the basin. In this case, the momentum of the incoming liquid partially or completely counteracts viscous flow resistance, and less of a variation in gravitational head is required. This ideal condition is reached if a Reynolds number appropriately defined for the primary channel is of the order of magnitude of unity so that the momentum of the incoming liquid is just sufficient to convey the liquid to the ends of the primary channel. ##EQU1## wherein: ρ is the density of the coating composition
μ is the viscosity of the coating composition
q is the volumetric flow rate per unit of curtain width
An effective inlet 25 has been found to be an enclosure with the walls opposite the endcaps of the basin 14 made of perforated plate. The supply conduit 16 is directed perpendicular to the lengthwise axis of the primary channel. The perforated side walls 27 are perpendicular to this axis so that the issuing liquid is directed toward the end caps of the basin. Flow resistance through the side walls distributes the liquid over the cross section of the channel. Ideally, the average velocity through the side walls based on the total open area of the perforations should approximate an average velocity based on the cross-sectional area of the primary channel. However, if the side walls are planar, the total area of all perforations must be substantially less than the channel area and the issuing velocity higher than desired. The open area of the sidewalls can be increased if their shape is corrugated rather than planar. Bends of 45 degrees, for example, increase the open area by about 41%. A section of sidewall that is slanted to the axis of the primary cavity produces an undesirable flow component across the cavity, and so it is desirable that for each slanted section there is an opposing section of equal area so that by symmetry there is no net cross flow. Bending the sidewalls to the shape of a bellows is a practical way to achieve the desired symmetry. Sidewalls of this shape are depicted in FIG. 8a and b.
Most advantageously, the sidewalls 27 of the inlet comprise a flat perforated plate in series with a perforated plate with angled, opposing sections. The flat plate is nearer the supply conduit, and its high flow resistance distributes the incoming liquid over the cross section. The plate comprising bent sections with a total open area more nearly that of the cross section of the primary cavity follows to reduce the velocity.
The front wall 28, shown in FIG. 8c, of the inlet opposing the dividing wall 13 is preferably separated from the dividing plate by a gap 29 (FIG. 8b) so that flow under the dividing plate is not blocked by the inlet. In the following example, the gap is 0.12 inches. The front wall of the inlet may have holes so that sufficient flow issues to supply that fraction of the cross section of the primary channel occupied by gap 29. The top surface 30 of the inlet extends to the dividing wall so that the liquid issuing from front wall 28 is forced under the dividing wall and down the primary channel. Any holes in the front wall of the inlet are preferably above the gap 24 between the dividing plate and the bottom of the basin so that direct jetting under the wall does not occur.
For uniform flow distribution, the flow rate through a cross section of the primary channel decreases approximately linearly with distance from the center as liquid supplies the curtain. So, if the primary cavity has a constant cross-sectional area, the velocity of the liquid in the primary cavity falls off as the end caps 14 are approached, as FIG. 9 illustrates. In FIG. 9, arrows in the primary channel indicate the average velocity and direction of the coating composition. The length of the arrows is proportional to the speed, and so the arrows indicate that the coating composition slows down as it flows from the center to the end of the primary channel. Low velocities may promote gravitationally induced inhomogeneity of the coating composition. The velocity of the liquid may be kept more uniform by tapering the cross-sectional area of the primary channel from the inlet to the cavity end, as shown by FIG. 10.
The geometric simplicity of the weir lends itself to economic fabrication. The weir may be assembled from separately machined elements, for example a main body and two endcaps, in the most demanding applications where tight tolerances must be met. In somewhat less demanding applications, the main body can be extruded from materials such as aluminum and cut to length. For the best demanding applications, the main body can be inexpensively formed from sheet material such as stainless steel sheet. Similarly, the dividing wall can be machined, extruded, or formed. A long dividing wall of small cross section can be mechanically stabilized with clips or brackets between the top of the dividing wall and the back (inlet) wall of the main body; positioning elements immersed in the coating composition disrupt flow and are undesirable. The endcaps can be replaced to vary curtain width, or blocks of different thicknesses conforming to the cross-sectional shape of the channels can be inserted into the secondary channel or into both of the channels and attached to a permanent endcap. If the inlet does not have its own floor or backwall so that the floor and back wall of the main body of the weir complete the inlet enclosure, then a tight fit is essential to prevent jetting of the coating composition through inadvertent gaps. Particularly undesirable is jetting along the floor of the weir directed under the dividing wall. In some applications, such as for highly volatile coating composition, a cover for the weir is beneficial.
EXAMPLE 1
A two-channel weir was constructed with the cross-sectional dimensions given in FIG. 11. Lengths are given in inches and angles in degrees. The gap under the dividing plate was 0.11 inches. The length of the two channels was 71 inches. The inner perforated sidewall of the inlet had holes 0.062 inches in diameter and a fractional open area of 30%. The outer perforated plate of the inlet had holes 0.075 inch in diameter and a fractional open area of 0.51; the six sections of this plate were angled at 60° to the cross section so as to oppose one another. A test liquid of polyvinyl pyrrolidone in water was prepared to which surfactant was added as known in the curtain-coating art. The fluid properties were a density of 1 gm/cc and a viscosity of 40 centipoise. Flow rate per unit width was 3.5 cc/sec per cm of curtain width. Under these conditions, the Reynolds number for the primary channel is 0.9 and has the preferred magnitude. Thus, good uniformity was achieved with a uniform gap. Reynolds numbers sufficiently higher or lower would have required tailoring the gap to achieve the desired uniformity in flow.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | 4y
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BACKGROUND OF THE INVENTION
The present invention relates to an article, a method for making same, and a method for protecting hydraulic lines, fuel lines and the like such as are typically found in aircraft engine applications, from extreme temperatures and flame impingement.
Flexible or bendable hydraulic hose lines and fuel hose lines are used in a wide variety of environments where they may be subjected to extreme temperatures in normal use and/or to flame impingement in an emergency situation. Also, in normal use the lines are exposed to dirt, water, hydraulic oil and fuel. In certain applications, such as in aircraft engines, the hydraulic fluid lines and the fuel lines must be protected for a sufficient period of time in the event of a fire to provide a response time for fire extinguishing equipment. In order to prevent rupture of these high pressure lines or delay rupture for a predetermined period, the lines are typically insulated with fire sleeving. The fire sleeving protecting such lines should be capable of preventing line rupture when exposed to flame and temperatures of up to 2000° F. for a period of 15 minutes.
Heretofore original equipment hydraulic and fuel lines have been typically provided with a fire sleeve including a braided asbestos material tubular core and a silicone rubber cover or coating. This type of original equipment sleeve is slipped over the line prior to installation of the line fittings. The original equipment sleeve cannot be replaced without removal of the fittings. In removing crimp type fittings, the hose is destroyed and the entire assembly must be replaced. Replacement therefore becomes costly and time consuming. The replacement procedure must be performed on a not infrequent basis since the sleeves wear out and replacement is required within approximately two years. In any event, replacement is required at time of a major engine overhaul.
In an attempt to alleviate some of the problems associated with replacement of the aforementioned type of original equipment fire sleeving, a spiral wrap sleeve has been proposed. This type of sleeve is defined by a three-ply, elongated, spiraled strip of silicone rubber coated asbestos. The strip is wrapped around the line in a spiral, overlaping manner. The resulting sleeve and hydraulic line combination has limited flexibility. The elongated seam defined by the spiral strip tends to separate or buckle upon bending of the combination to various curvatures. Also, the elongated, spiral seam which runs around the line and extends the length thereof, permits fuel, dirt and hydraulic fluid contaminants to enter the sleeve between the spirals. In a fire situation, the contaminants may support combustion and therefore reduce the protection capabilities of the sleeving. The spiral wrap sleeve, therefore, may not adequately protect the hydraulic or fuel line.
SUMMARY OF THE INVENTION
A need therefore exists for a fire sleeve for protecting high pressure hydraulic and fuel lines and the like from temperature extremes which is easily and readily installed on such a line at the point of manufacture, in the field or as a replacement item without necessitating removal of the line fittings, provides a flexible sleeve and line combination, eliminates ingress of dirt, fuel or oil and is resistant to flame, dirt, oil, water, fuel, ozone and fungus. Essentially, the sleeving in accordance with the present invention includes a silicone polymer coated glass fiber sheet which is self coiling and normally assumes a coiled, generally cylindrical configuration.
In narrower aspects of the invention, the sheet is a woven glass fiber sheet cut along a full bias to provide increased flexibility of the sleeving and line combination than has heretofore resulted. The normally coiled configuration of the sleeving has at least a two-ply thickness, the lateral edges overlap and the sheet is physically and chemically stable for use in an environment having a temperature range of -100° F. to 600° F. The silicone polymer coating on the outside of the sleeve is of a fire retardant composition and of a thickness and composition different from that on the inside inner surface of the sleeve.
The method comtemplated by the present invention includes the steps of uncoiling a resiliant, generally cylindrical normally coiled silicone polymer coated and impregnated glass fiber sheet, placing the uncoiled sheet along the hydraulic or fuel line and letting the sheet snap back to its normally coiled shape so that the lateral edges thereof overlap to define a fire sleeve having a longitudinal seam, and applying a high temperature sealant along the longitudinal seam of the sleeve.
The method fabricating the fire sleeve involves coating a fibrous glass sheet on both sides with silicone polymer, wrapping the sheet on a mandrel, precurring the sheet, and subjecting the sleeve to a post cure treatment to drive flame supporting volatiles from the sleeve.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevational view of a fire sleeve in accordance with the present invention;
FIG. 2 is an end elevational view of the fire sleeve of FIG. 1;
FIG. 3 is a fragmentary, side elevational view of a portion of the fire sleeving;
FIG. 4 is a top, plane view showing the manner in which the sheet defining the fire sleeving is cut along a 45° bias;
FIG. 5 is an end, elevational view of mandrel upon which the sheet has been wrapped during the manufacturing process; and
FIG. 6 is a plan view of a hose and fire sleeve combination in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the unique fire sleeve in accordance with the present invention is illustrated in FIGS. 1, 2 and 3 and generally designated 10. Fire sleeving 10 includes a woven glass fiber sheet 12 having a fire retardant silicone polymer coating 14 on its upper surface and a high temperature silicone polymer coating 16 on its lower surface. The fire sleeving 10 is resilient and assumes a normally coiled, generally cylindrical configuration with the lateral edges 18, 20 overlapping through an arc angle generally designated "a" in FIG. 2. As explained below, the glass fiber sheet 12 is "laid up" on a full 45° bias resulting in an increase in the flexibility of the fire sleeve and hose combination.
In a presently existing embodiment of the fire sleeving in accordance with the present invention, the coating 14 is a fire retardant silicone rubber. The presently preferred material for the coating 14 is Dow Corning Silastic S2365 silicone rubber. This rubber has a red color, a specific gravity of 1.19, a brittle point of -103° F. and a chemical classification ASTM D1418 of VMQ. The rubber is prepared with a 2,4-dichlorobenzoyl peroxide (Cadox TS-50 or Lupercko CST) type vulcanizing agent. A fully catalyzed vulcanizing agent level is employed. Based upon a 0.075 inch thick slab, press molded 5 minutes at 116° Centigrade (240° F.) and post-cured for one hour at 200° Centigrade (392° F.), this type of silicone rubber has a Shore A Durometer of 40, a tensile strength of 900/psi, an elongation modulus of 700%, a tear strength, Die "B" of 75/ppi, a bond strength (rubber to glass cloth) of 10/ppi and flame resistance characteristics according to Dow Corning test CPM-0451 (reference FED. 191-5903.1) of a 12 second flame time and a char length of 1 inch. The coating 14 is preferably coated onto the glass fiber sheet to a thickness of 8 mil. by a conventional calender process.
The silicone coating 16 also applied by a calender process is preferably Dow Corning Silastic 451OU silicone rubber. This silicone rubber has a light straw color, a specific gravity of 1.19, a brittle point of -73° Centigrade (-100° F.) and a chemical classification ASTM D1418 of VMQ. The rubber is prepared with a 2,4-Dichlorobenzoyl Peroxide (Cadox TS-50 or Lupercko CST) type vulcanizing agent--a fully catalyzed vulcanizing agent level is employed.
Typical properties of silicone rubber 16 based upon a 0.075 inch thick slab press molded 10 minutes at 150° C. (302° F.) include a Shore A Durometer of 54, a tensile strength of 900/psi, an elongation modulus of 300%, a Die "B" tear strength of 55/ppi and a compression set 70 hours at 150° C. (302° F.) of 26%.
Both of the forementioned silicone coatings 14, 16 are readily available commercial items which may be purchased through Dow Corning Corporation, Midland, Michigan.
It is presently preferred that the glass fiber sheet 12 be a 20×18, plain weave glass (0.016), ECE 225-4/3W & F yarn having a gauge of 0.060+0.005 inches.
As an initial step in the manufacture of the sleeve, coatings 14 and 16 of silicone rubber are calender coated onto the surfaces of a large glass fiber sheet. As seen in FIG. 4, the coated woven sheet may then be cut along lines 21 at a 45° bias or a full bias to form strips which define sheets 12. The ends of the resulting cut strips may be trimmed square. In the alternative, the sheet could be cut prior to coating. The strips or cut sheets 12 are wound on a mandrel 22, as seen in FIG. 5, in an "envelope" fashion to the required number of plies (3 shown). The thicker coating 16 is wrapped against the mandrel. Prior to wrapping, both surfaces of the coated strip are sprayed with a McLube and teflon spray. A piece of one half inch wide cellophane is placed under the outer seam defined by the lateral edge 18 to prevent bonding of the seam to the sheet. A cellophane wrap is applied for pre-cure and the mandrel and sheet are placed in an oven and pre-cured for 15 minutes at 350° F. Next, the cellophane wrap is removed and the partially cured or pre-cured sleeve is cooled (water bath) and removed from the mandrel. The cellophane is removed from under the overlapped seam area 18 and the sleeve is uncoiled. The sleeve surfaces are then dusted with a Mica dust. Finally, the sleeve is subjected to a two-step post-cure. First, the sleeve is post-cured for a total period of 12 hours with a temperature starting at 150° F. and raising to 480° F. at which it is held for 5 hours. The sleeve is then post-cured at 550° F. for a period of 15 minutes. This two-step post-cure insures that all of the flame supporting volatiles in the silicone rubber coatings 14, 16 are driven from the sleeve.
The resulting fire sleeving manufactured in accordance with this procedure from the preferred materials will be chemically and physically stable within acceptable service limits for use in environments experiencing a temperature range of -100° F. to +600° F. The -100° F. temperature represents the brittle point for the fire sleeving. At the upper end of the temperature range, the service life of the sleeve will be shortened since the silicone material may start to dry and deteriorate. The usuable temperature range permits the product to be employed in aircraft structure and engine environments.
The preferred embodiment of the sleeving 10 conforms to Mil-y-1140F, Class C, Form 4 fabric specification and has a ply adhesion of 8 lbs. per inch after a 5 hour 480° F. post-cure based upon a test sample 1 inch wide and a 2 inch/min. peel. The sleeving has an acceptable service flexibility at -75° F. and a minimum acceptable service life of 72 hours with a continuous room ambient temperature of 600° F.
As seen in FIG. 6, the fire sleeving 10 is easily installed upon hoses of the type employed for hydraulic oil and fuel applications by the aircraft industry. The hoses typically are stainless steel wire braid reinforcement over an extruded tube of Teflon with permanently attached, compression end fittings 26, 28. The fire sleeving 10 which is preferrably fabricated in standard lengths to fit standard size hoses, is uncoiled and snapped onto the hose and secured thereto with band clamps 30, 32. The sleeving may be notched at the corners so that the ends are generally T-shaped in plan. The sleeving will then fit over the crimped ends of the fittings without bulging. A high temperature silicone adhesive 34, partially shown in FIG. 6, is preferrably applied along the lateral seam defined by the edge 18 of the coiled sleeving 10. The adhesive seals the seam and prevents ingress of oil, water, dirt, fuel and the like. It is presently preferred that a high temperature silicone adhesive of the type manufactured by General Electric Company and distributed under the brand name RTV 106 be employed to seal this lateral seam. The band clamps 30, 32 need not be used and the high temperature RTV 106 silicone may be used to seal the area of the end fittings.
The resulting fire sleeve and hoseline combination in accordance with the preferred embodiment meets the 15 minute, no leakage test requirements of ARP 1055 for Type 2D, Class B-S/P as performed per FAA TSO C-53A. A two-ply sleeve with an arc angle "a" overlap of at least 35°, when subjected to flame impingement at temperatures of approximately 2000° F., protects the hose and prevents leakage. During flame impingement, the silicone coating 14 on the outer surface will "ash". As the coating ashes, it ablates or falls off of the sleeving. The thicker coating 16 and the inner layers of coating 14 will also ash but will be held in place around the hose by the glass fiber sheet 12. The "ashing" increases the insulating characteristics and the sleeving creates a barrier between the flame and the hose. The ashing of the coatings will begin at temperatures of approximately 1200° F. to 1300° F.
Since the sleeve is fabricated from elongated strips of woven glass fiber sheets cut along a 45° bias, the sleeving 11 and hose flexibility is increased from that heretofore provided. The bendable hose may be routed in accordance with environmental needs and the fire sleeving will flex or bend with the hose without buckling or separation of the longitudinal seam.
The fire sleeving is preferably manufactured in a range of sizes to fit standard hose. For example, fire sleeving having a nominal ID of 0.312 for -4 size hose having a nominal ID of 0.187; a nominal ID of 0.386 inch for -5 size hose having a nominal ID of 0.250, a nominal ID of 0.445 inch for -6 size hose having a nominal ID of 0.312; a nominal ID of 0.549 for -8 size hose having a nominal ID of 0.406; a nominal ID of 0.648 for -10 size hose having a nominal ID of 0.500; a nominal ID of 0.778 for -12 size hose having a nominal ID of 0.625; a nominal ID of 1.109 for -16Z size hose having a nominal ID of 0.875; a nominal ID of 1.359 for -20Z size hose having a nominal ID of 1.125; and a nominal ID of 1.672 for -24Z size hose having a nominal ID of 1.375.
As should now be readily apparent to those of ordinary skill in the art, the present invention provides significant advantages over prior sleeving. The fire sleeving in accordance with the present invention will conform to the fire resistance and fire test requirements for fluid system components promulgated by the Society of Automotive Engineers, Aerospace Recommended Practice, ARP 1055 issued Feb. 1, 1969. The fire sleeving is easily installed as a replacement item in the field since the original equipment "slip-on" type sleeve may be removed and the sleeve in accordance with the present invention uncoiled and "snapped on" the existing line. This results in a substantial reduction in the cost of major aircraft engine and structure overhauls. It is no longer necessary to replace the entire hoseline/fire sleeve combination. The fire sleeving is resistant to extreme temperatures and usable within the temperature range of -100° to 600°. The sleeving meets the flame test requirements currently employed in the industry, is resistant to oil, dirt, water, fuel and fungus and is easily manufactured and installed. The coiled configuration presents only a single seam. When sealed as set forth above, ingress of flame supporting materials is prevented. The sleeve will "flex" in use and buckling or separation along the seam is eliminated.
It is expressly intended, however, that the above description should be considered as that of the preferred embodiment. Various modifications will undoubtedly now become apparent to those of ordinary skill in the art in view of the above description. For example, the thickness of the silicone coatings could be increased without affecting the performance of the fire sleeving. Also, the number of plies could be increased. Therefore, the true spirit and scope of the present invention may be determined by reference to the appended claims. | 4y
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This is a continuation application of Ser. No. 819,057, filed Jan. 15, 1986, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a wafer inspecting apparatus for inspecting a semiconductor wafer.
2. pk Description of the Prior Art
It is already known to control two units of a wafer inspecting apparatus with a tester apparatus. However such a system requires a very large floor space for installation, since each wafer inspecting apparatus is equipped not only with a stage mechanism capable of fine alignment for wafer inspection but also with a loading mechanism for bringing the wafer to the stage mechanism.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an automatic wafer aligning apparatus, capable of accurate and rapid positioning of semiconductor wafers.
Another object of the present invention is to provide a wafer inspecting apparatus capable of inspecting semiconductor wafers with plural stage mechanisms and requiring only a small floor space for installation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial view of a wafer inspecting apparatus;
FIG. 2 is a partial view thereof;
FIG. 3 is a cross-sectional view, along a line A--A shown in FIG. 2, indicating a loading mechanism of the wafer inspecting apparatus;
FIG. 4 is a flow chart indicating the control procedure of a microcomputer;
FIGS. 5A and 5B are schematic views showing a partial improvement in the apparatus shown in FIG. 2;
FIG. 6A is a schematic view showing a structure for pre-alignment in the apparatus of the present invention;
FIG. 6B is a schematic view showing a structure for fine alignment in the apparatus of the present invention;
FIG. 7 is a schematic view showing the principle of scanning at image taking;
FIG. 8 is a schematic view showing edge dots on a wafer;
FIG. 9 is a chart showing a change in data of FIG. 8;
FIG. 10 is a chart showing an example of data processing for a wafer;
FIG. 11 is a flow chart indicating a pre-alignment procedure;
FIG. 12 is a schematic view showing the relationship between streets on a wafer and a line sensor;
FIG. 13 is a chart showing the wave form of an output signal of a line sensor positioned on a street shown in FIG. 12;
FIG. 14 is a schematic view showing the relationship between streets on a wafer and a line sensor;
FIG. 15 is a chart showing the wave form of an output signal of a line sensor positioned on a street shown in FIG. 14;
FIG. 16 is a flow chart showing a fine alignment procedure;
FIG. 17 is a plan view showing a principle of encoded data reading;
FIG. 18 is a schematic view showing a principle of first chip retrieval;
FIG. 19 is a chart showing the wave form of an output signal of a line sensor positioned on an end street shown in FIG. 18;
FIG. 20 is a chart showing a principle of original point location in the alignment on the x-axis;
FIG. 21 is a chart showing the wave form of an output signal of a line sensor positioned on a street shown in FIG. 20; and
FIG. 22 is a block diagram showing a control system for use in the apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now the present invention will be clarified in detail by an embodiment thereof shown in the attached drawings.
In FIG. 1 there are shown a support frame 1 and vibration preventing mechanisms 2, 3 independently provided on the support frame 1. On the vibration preventing mechanism 2 there is fixed a base 4, on which is provided an X-Y stage 5 for movement in X- and Y-directions on the base 4. On the X-Y stage 5 there is provided a Z-stage 6 for movement in the Z-direction. A θ-rotation stage 7 is provided on the Z-stage 6 to achieve rotational movement thereon. These stages (X-Y, Z, θ) are respectively driven by motors. A wafer 8 is placed on the θ-rotation stage 7, which is equipped with a suction mechanism to support the wafer thereon by vacuum suction. A probe card 9 is fixed on a support 10 extended from the base 4. A microscope 11 is fixed on a casing 12 for observing the wafer 8 placed on the stage 7. A CCD linear sensor 13 scans the wafer 8 for aligning the same. An IC chip formed on the wafer 8 is brought into contact with probe needles 9a by vertical movement of the Z-stage 6. The signals obtained from probe needles 9a are supplied, through the probe card 9, to a tester separate from the wafer inspecting apparatus, and an inspection output concerning the wafer 8 is obtained from the tester. Naturally the tester may be integrally constructed with the wafer inspecting apparatus. In the present embodiment, a right-hand inspection unit is composed of the above-explained components 4-7, 9-11 and 13. A left-hand inspection unit is composed of a base 14, an X-Y stage 15, a Z-stage 16, a θ-rotation stage 17, a probe card 19, a support 20, a microscope 21 and a sensor 22 which are respectively the same as the components 4-7, 9-11 and 13 of the right-hand inspection unit. A wafer 18 is placed on the θ-rotation stage. The right-hand inspection unit and the left-hand inspection unit are respectively supported by the vibration preventing mechanism 2, 3 independently provided on the support frame 1, and these mechanisms prevent mutual transmission of vibration. A control unit 23 is provided with a microcomputer (MCU) 23a provided with a calculating unit, memories, an I/O port etc. and controls the stages 5-7, 15-17, a wafer carrier transport mechanism, and a wafer loading mechanism to be explained later.
In the following there will be explained the wafer carrier transport mechanism and the wafer loading mechanism. These mechanisms are respectively housed in 31 and 32 shown in FIG. 2. Wafer cassettes 33a, 33b, each containing plural wafers are transported by a transport mechanism (not shown) in succession to a position B. The cassette 33a brought to the position B is supported on a table 34a shown in FIG. 3 and is elevated to a broken-line position by an elevator 34. A motor 35 shown in FIG. 3 vertically drives the table 34a of the elevator 34. The elevator 34 and the motor 35 constitute a part of the above-mentioned transport mechanism. A support member 36 fixed on the support frame 1 is provided with a guide member 37 and a worm 38 which is driven by a motor 39. A motor 40 is provided with a worm gear (not shown) meshing with worm 38, and moves to the left or to the right along the X-direction in FIG. 3 by the forward or reverse rotation of the motor 39, along the guide member 37. The motor 40 is provided with a shaft 41 to which an arm 42 is attached. The arm 42 is rotated clockwise or anticlockwise about the shaft 41 in FIG. 2, by the forward or reverse rotation of the motor 40. In the present embodiment the wafer loading mechanism is composed of the above-mentioned components 36-42. A support member 43 is fixed on the support frame 1 and supports a motor 44 which rotates a stage 45 for prealignment of the wafer.
Now reference is made to FIG. 4 for explaining the function of the apparatus of the present invention.
At first, in response to an instruction from the MCU 23a in the control unit 23, the transport mechanism brings the cassettes 33a, 33b in succession to the position B, and the cassette brought to position B is elevated to the broken-line position shown in FIG. 3 by the elevator 34. In step 100 the MCU 23a identifies if a wafer is present on the θ-rotation stage 7. If not, step 101 identifies whether a wafer is present on the prealignment stage 45. If absent again, step 102 outputs an instruction to bring a wafer to pre-alignment stage 45. Then the loading mechanism and the prealignment stage function in the following manner according to a subroutine of the MCU 23a. At first the motor 39 is activated in the forward direction to shift the motor 40 to the left in FIG. 3, whereupon a wafer contained in the cassette 33a is placed on the arm 42. Then the motor 39 rotates in the reverse direction, thereby shifting the motor 40 and the arm 42 to the right. The motor 40 is then stopped at a suitable position, and is activated to rotate the arm 42 by 180° about the shaft 41. In this manner the wafer is brought to the position of the pre-alignment stage 45 and is placed thereon. Subsequently the motor 40 is shifted to the left by the rotation of the motor 39 and returns to the position shown in FIGS. 2 and 3. However the arm 42 remains directed toward the stage 45. The stage 45, supporting the wafer, effects pre-alignment by rotation. Upon completion of the wafer pre-alignment, the MCU 23a outputs an instruction, in step 103, to set the wafer on the θ-rotation stage 7. In case step 101 identifies the presence of a wafer on the stage 45, and if the pre-alignment is already completed, the program proceeds directly to step 103. On the other hand, in case step 101 identifies the presence of a wafer on the stage 45 but the pre-alignment is not yet completed, the pre-alignment is continued, and, upon completion thereof, the program proceeds to step 103. In response to the instruction in step 103, the loading mechanism and the fine alignment stages (X-Y, Z and θ-stages 5-7) function in the following manner according to a subroutine of the MCU 23a. At first the motor 39 is rotated in the reverse direction to shift the motor 40 to the right, together with the arm 42 directed toward the pre-alignment stage 45. After the pre-aligned wafer is placed on the arm 42, the motor 39 is rotated in the forward direction to shift the motor 40 to the left in FIG. 3.
Thus the motor 40 returns to the position shown in FIGS. 2 and 3. Then the motor 40 is rotated in the forward direction to rotate the arm 42 clockwise, in FIG. 2, by 90°, thereby bringing the wafer to a position C. At the same time the X-Y stage 5 is driven by a motor (not shown) to bring the θ-rotation stage 7 also to the position C. In this manner the wafer is placed on the θ-rotation stage 7, which fixes the wafer by suction. Subsequently the motor 40 is rotated in the forward direction to rotate the arm 42 by 90° clockwise, thus bringing it to the state shown in FIG. 2. Also the θ-rotation stage 7 returns to the position shown in FIGS. 1 and 2 by the movement of the X-Y stage 5. Then the MCU 23a drives the X-Y stage in the X- and Y-directions, illuminates the wafer with an illuminating optical system (not shown) and receives reflected light from the wafer with the sensor 13, thereby obtaining information on the position of chips formed on the wafer. Based on this information, the MCU 23a finely moves the stages 5-7 to achieve fine alignment of the wafer. The wafer 8 shown in FIG. 1 shows a state after such alignment. Upon completion of the fine alignment of the wafer 8, the MCU 23a supplies a signal to the tester, and simultaneously drives the Z-stage 6 with a motor (not shown) to elevate the θ-rotation stage 7. In this manner the chip formed on the wafer 8 is brought into contact with the probe needles 9a and is inspected by the tester. Upon completion of the chip inspection, the MCU 23a outputs a signal to drive the Z-stage 6, thereby lowering the θ-rotation stage 7. Then the X-Y stage 5 is moved by one chip, and the θ-rotation stage 7 is elevated to bring the next chip into contact with the probe needles 9a for inspection by the tester. Plural chips formed on the wafer 8 are inspected by repeating the above-explained procedure. After outputting the wafer setting instruction in step 103, the MCU 23a immediately proceeds to step 106 to identify whether a wafer is present on the θ-rotation stage 17, without awaiting the completion of the above-explained wafer inspection. Consequently the above-explained procedure of wafer setting, fine alignment and wafer inspection is conducted simultaneously with discrimination step 106 and ensuing steps. In case step 100 identifies the presence of a wafer on the θ-rotation stage 7, the MCU 23a identifies, in step 104, whether the wafer on stage 7 is already inspected. If not, the MCU 23a continues the wafer setting on the stage 7, fine alignment of the wafer and wafer inspection, and immediately moves to step 106, without awaiting the completion of wafer inspection. In this manner the procedure of wafer setting, fine alignment and wafer inspection is conducted simultaneously with discrimination step 106 and the ensuing steps. On the other hand, if step 104 identifies the completion of wafer inspection, the MCU 23a outputs an instruction, in step 105, to return the wafer from the θ-rotation stage 7 to the carrier 33a. In response the loading mechanism and the fine alignment stage function in the following manner, according to a subroutine of the MCU 23a. At first the motor 40 is activated in the reverse direction to rotate the arm 42 by 90° anticlockwise from the position shown in FIG. 2. Simultaneously the X-Y stage 5 is activated to shift the θ-rotation stage 7 to the position C. Then the vacuum suction is terminated and the wafer 8 is placed on the arm 42. Subsequently the stage 7 is shifted to a position shown in FIG. 2. However stage 7 may remain at the position C until the next wafer arrives. After the wafer 8 is placed on the arm 42, the motor 40 is activated in the forward direction to rotate the arm 42 by 90° clockwise in FIG. 2, thus returning arm 42 to the position shown in FIG. 2. Subsequently the motor 39 is activated in the forward direction to shift the motor 40 to the left, thereby returning the wafer into the wafer cassette 33a. Then the motor 40 returns to the position shown in FIG. 3, by the rotation of the motor 39. After return of the motor 40, the MCU 23a returns to step 100. When the MCU 23a proceeds from step 103 or 104 to step 106, there is identified whether a wafer is present on the θ-rotation stage 17. If absent, step 107 identifies whether a wafer is present on the pre-alignment stage 45. If absent again, step 108 outputs an instruction to bring a wafer to pre-alignment stage 45. Thus a wafer is brought from the cassette 33a to the pre-alignment stage 45 in the same manner as in step 102, thereby conducting pre-alignment of the wafer. Upon completion of pre-alignment, step 109 releases an instruction to set the wafer on the θ-rotation stage 17. On the other hand, in case step 107 identifies the presence of a wafer on the stage 45, there is thereafter conducted a procedure the same as that when the presence of a wafer is identified in step 101. In response to the instruction in step 109, the MCU 23a controls the loading mechanism and the stages 15-17 according to a subroutine, in the same manner as the wafer setting from the stage 45 to the stage 7, fine alignment of the wafer and wafer inspection in step 103. However the control in step 109 is different from that in step 103 in the rotating direction of the arm 42, in that the stages 15-17 are activated instead of the stages 5-7, in that the stage 17 is brought to a position θ at the wafer setting thereon, and in that the wafer on the stage 17 is inspected by the probe needles 19a.
In this manner the wafer is set on the stage 17, then subjected to fine alignment and inspected. The wafer inspection is conducted with the same tester mentioned before. After outputting the wafer setting instruction in step 109, the MCU 23a immediately moves to step 112 to identify whether a wafer is present on the pre-alignment stage 45, without awaiting the completion of wafer inspection. Consequently as in the aforementioned steps 103 and 106, the procedure of the wafer setting, fine alignment of the wafer and wafer inspection is conducted simultaneously with the discrimination step 112 and ensuing steps. On the other hand, in case the presence of a wafer on the prealignment stage 45 is identified in step 106, the MCU 23a identifies, in step 110, whether the wafer on the θ-rotation stage 17 is already inspected. If not, the MCU 23a continues the wafer setting on the stage 17, fine alignment thereof and wafer inspection, and immediately proceeds to step 112 without awaiting the completion of wafer inspection. Thus, as in the aforementioned steps 104 and 106, the procedure of wafer setting, fine alignment and wafer inspection is conducted simultaneously with the discrimination step 112 and ensuing steps. If step 110 identifies the completion of wafer inspection, the MCU 23a outputs, in step 111, an instruction to return the wafer from the stage 17 to the cassette 33a. In response the loading mechanism and the fine alignment stages 15-17 function according to a subroutine of the MCU 23a, whereby the wafer 18 on the stage 17 is returned to the cassette 33a in the same manner as in step 105 and the state shown in FIGS. 2 and 3 is restored. However the above-mentioned procedure is different from that of the step 105 in rotating direction of the arm 42, in that the stages 15-17 are activated and in that the stage 17 is brought to a position D. When the loading mechanism is returned to the state shown in FIGS. 2 and 3, the MCU 23a returns to step 106. The MCU 23a, upon proceeding from step 109 or 110 to step 112, identifies whether a wafer is present on the pre-alignment stage 45, and, if absent, outputs an instruction in step 113 to transfer a wafer to stage 45. Then, according to a subroutine of the MCU 23a, in the same manner as in steps 102 and 108, a wafer stored in the cassette 33a is brought to the pre-alignment stage 45 and is subjected to pre-alignment. Upon completion of the wafer pre-alignment, the MCU 23a returns to step 100. The procedure in case step 112 identifies the presence of a wafer on the stage 45 is the same as when the presence of a wafer on the stage 45 is identified in step 101 or 107. Upon completion of the pre-alignment, the MCU 23a returns to step 100.
In the present embodiment, if the loading mechanism receives a second instruction while it is operated under a first instruction, for example the instructions in steps 103 and 111, the loading mechanism executes the second instruction after the operation according to the first instruction is completed. However the time from the wafer setting on the θ-rotation stage 7 or 17 to the completion of wafer inspection is much longer than the functioning time of the loading mechanism. Consequently it is not expected that the loading mechanism will receive two instructions at the same time as mentioned above.
In the present embodiment, the discrimination in step 100, 101, 104, 106, 107, 110 or 112 is achieved by the MCU 23a itself through identification of the control status of the loading mechanism, pre-alignment stage, fine alignment stage etc. according to the flow chart shown in FIG. 4. For example the discrimination of step 100 is achieved in the following manner. The MCU 23a identifies that the θ-rotation stage does not have a wafer, if the arm 42 has completed an operation of receiving the wafer from the stage 7 and if a wafer supply operation from arm 42 to the stage 7 has not been conducted.
The motors 35, 39, 40, 44 and the motors (not shown) for driving the stages 5-7, 15-17 are driven by signals supplied from the MCU 23a through drivers (not shown).
The wafer cassette is removed by the transport mechanism, when the wafer inspection is completed for all the wafers contained in a cassette, and a new wafer cassette is brought to the position B. Thereafter the above-explained stages of loading, pre-alignment, wafer setting, fine alignment and wafer inspection are repeated.
In the present embodiment, as explained in the foregoing, it is possible to load and inspect a wafer in an inspection unit (steps 106-109 or 100-103) while another wafer is inspected in the other inspection unit (step 103 or 109).
In the foregoing description, the program is designed to proceed from step 105 to 100 and from step 111 to 106, but it may also be designed to proceed from step 105 to 112 and from step 11 to 112.
In addition, electromagnetic shield members 46, 47 may be provided as indicated with broken lines in FIG. 2, in order to reduce the influence to an inspection unit of electromagnetic noise generated in the other inspection unit. The use of such shield members is desirable, therefore, in case considerable electromagnetic influence is anticipated between the inspection units.
An apparatus shown in FIGS. 5A and 5B is provided with a distribution mechanism with an arm 111A rotatable about a shaft 111B, and a microscope 110 is provided at the end of arm 111A as observing means. The microscope 110 is rotatable, with respect to the end of the arm 111A, about the optical axis of an objective lens 110A which is parallel to the above-mentioned shaft 111B, so that the eyepiece 110B of the microscope 110 can be directed to the front side of the apparatus regardless of the rotational position of the arm 111A.
Stated differently, the microscope 110 can revolve both around the shaft 111B and on the optical axis of the objective lens 110A. Except as explained above, the structure of the apparatus is identical with that of the apparatus shown in FIGS. 1, 2 and 3.
When a chip formed on the wafer 8 is brought into contact with the probe needles 9a by the elevation of the θ-rotation stage, the operator moves the microscope 110 to the broken-line position in FIG. 5A to observe the contact state of the chip and the probe needles 9a. On the other hand, at the inspection of the chip formed on the wafer 8, the microscope 110 is brought to the full-line position.
As shown in FIG. 6A, the arm 42 for extracting the wafer 100' from the wafer cassette is provided at the front end thereof with a vacuum chuck 42a for fixing the wafer by suction.
At a suitable position above arm 42, there are provided a CCD line sensor 53 in which photodiodes are arranged in the Y-direction, an optical system 54 and a light source 55. The light emitted by the light source 55 is reflected by the wafer 100', and is focused onto the line sensor 53 by the optical system 54, whereby the pattern on the wafer 100 can be captured as a linear image. Thus, the surface of the wafer 100' is scanned by a movement of the wafer 100' in the direction of arrow F2 parallel to the X-axis, and corresponding image signals are produced from the line sensor 53.
Also as shown in FIG. 6B, the stage 7 is provided with a vacuum check 7a for fixing the wafer by suction.
Above stage 7 there are provided a CCD line sensor 13 in which photodiodes are arranged in the Y-direction, an optical system 61, a light source 62 and a half mirror 63, whereby the light emitted from the light source 62 passes through the half mirror 63, is then reflected by the wafer 100' and enters the line sensor 13 through the half mirror 63 and the optical system 61. An arrow F3 is parallel to the X-axis.
In the apparatus of the present invention, the alignment operation is controlled by the microcomputer 23a. In the following description reference will be made to a flow chart shown in FIG. 11 for explaining the pre-alignment procedure. At first, in step 200, the microcomputer 23a activates the arm 42 to extract a wafer 100' from the wafer cassette by vacuum suction. The wafer 100' is then moved in the direction of arrow F5 for transfer to the stage 45. In the course of this movement, step 201 is executed whereby the output signals of the line sensor 53, representing the image on the wafer 100', are read after A/D conversion. The image signals thus obtained are subjected to data processing in the microcomputer 23a to determine the wafer size, and the position of the center of the wafer or of the orientation flat of the wafer. As shown in FIG. 6A, the light from the light source 55 is reflected by the wafer 100' during the movement thereof in direction F5, is then reduced in size by the optical system 54 and guided to the line sensor 53. In this manner the surface of the wafer 100' is scanned as represented by vertical lines in FIG. 7, and corresponding image signals are produced from the line sensor 53.
Step 202 detects, from the image signals, points corresponding to the edge of the wafer 100' as shown in FIG. 8, wherein the x-axis represents the amount of movement of the arm 42 while the y-axis corresponds to the positions of plural photodiodes. Said points are determined from the contrast between the wafer 100' and the background. Succeeding step 203 detects the wafer size, which is determined as the maximum of the distance the in Y-direction of two edge points shown in FIG. 8.
Then step 204 calculates the rate of variation, slope or differential, of the lines connecting the points shown in FIG. 8, thus obtaining the result shown in FIG. 9, wherein the y'-axis represents the rate of variation. A line C1-C2 represents the rate of variation of the upper line in FIG. 8, and a line D1-D2 represents the rate of variation of the lower line in FIG. 8.
In case the orientation flat 100a of the wafer 100' is not parallel to the y-axis or the the direction of array of the line sensor 53, as shown in FIG. 8, the rate of variation remains constant in a portion corresponding to the orientation flat, as exemplified by line E-F in FIG. 9. Therefore, the orientation flat 100a is identified as parallel to the y-axis if there is no such portion in which the rate of variation is constant, and, if otherwise, the orientation flat 100a is identified as not parallel to the y-axis. Also the position of the orientation flat 100a, i.e. above or below the x-axis, can be determined from whether such portion appears in the line C1-C2 or D1-D2.
Step 205 determines, in case the orientation flat 100a is not parallel to the y-axis, the direction thereof or the angle thereof to the x-axis. Referring to FIG. 10, angle θ between the x-axis and a vertical line to the orientation flat, passing through a temporary center H, determined in advance on the x-axis, is represented by: ##EQU1## wherein (xE, yE) and (xF, yF) are coordinates of end points E, F of the orientation flat, as shown in FIG. 10. The direction of the orientation flat can be determined from this equation.
Next step 206 calculates the position of center G of the wafer 100'. Two lines K-L, M-N, respectively parallel to the y- and x-axis are assumed on the wafer 100' but outside the orientation flat 100a, with coordinates K(xK, yK), L(xL, yL), M(xM, yM) and N(xN, yN). The coordinates (xG, yG) of the center G of the wafer 100' is represented by: ##EQU2##
The distance between center G and the aforementioned temporary center H is determined by:
Dx=xG-xH (4)
Dy=yG-yH (5)
wherein (xH, yH) are the coordinates of temporary center H, wehrein yH=0. Step 207 causes the arm 42 to load the wafer 100 on the stage 45. Step 208 rotates the stage 45 supporting the wafer 100' by the angle θ calculated in step 205, whereby the rotational aberration of the wafer 100' to the apparatus at the loading onto the stage 7 by the arm 42 is practically cancelled. Step 209 moves the X-Y stage to the position C shown in FIG. 2, and step 210 causes the arm 42 to load the wafer 100' on the stage 7. The above-mentioned values Dx, Dy are used as correction values in the displacement of the stage 7 from the position C shown in FIG. 2 in step 209, prior to the loading of the wafer 100 from the arm 42 to stage 7. More specifically, the stage 7 is displaced from the position C in such a manner that the center of stage coincides with the point G, whereby the center G of the wafer 100' coincides with the center of stage 7.
Now reference is made to FIG. 16 for explaining the fine alignment procedure in the apparatus of the present invention.
At the loading of the wafer from the arm 42 to the stage 7, plural pins are temporarily pushed out from stage 7 to lift the wafer 100' from the arm 42. In this state the arm 42 is extracted, and pins are retracted to place the wafer 100' on the stage 7. For conducting this operation, the front end of the arm 42 is square U-shaped.
The pattern on the wafer 100' placed on the stage 7 is determined, through the optical system 61, by the line sensor 13. The corresponding output signals from line sensor 13 are supplied, after A/D conversion, to the microcomputer 23a for fine alignment.
At first, in step 300, the microcomputer 23a drives the stage 5 in such a manner that the center G of the wafer 100' approximately coincides with a reference position of the apparatus.
Output signals of the line sensor 13 are read in step 301. As an example, reading an area QA in FIG. 12 provides image data as shown in FIG. 13(A). So-called streets 58, which are unexposed areas between the chips on the wafer, have higher reflectance and give rise to signal level changes as shown in FIG. 13(A). When the wafer 100' is shifted, in step 302, by one chip size as represented by area QB, the edges of the output signals of the line sensor 13 are slightly shifted as shown in FIG. 13(B), since the streets 58 and the line sensor 13 are not necessarily orthogonal. Step 303 reads the output of sensor 13.
Step 304 calculates the angle θA. The inclination angle θA of the street 58 to the line sensor 13 is given by: ##EQU3## wherein y1, y2 are edge positions and cx is the chip size. Step 305 rotates the wafer 100' by angle θA by means of the stage 7.
Then step 306 moves the wafer 100' at a pitch corresponding to the chip size in the positive x-direction, with respect to the line sensor 13 as shown in FIG. 14. There is therefore determined a position x 1 , at which the output of the line sensor 13 does not show the distribution shown in FIG. 13, or at which a street 58 cannot be found, and a position x 2 which is inside the position x 1 by one chip size. This is defined as the end position in the positive x-direction. Similarly the wafer 100' is stepwise moved by one chip size in the negative x-direction, and there are determined a position x 4 at which the street 58 cannot be found, and an end position x 3 which is inside position x 4 by one chip size.
Step 307 calculates an inclination correcting angle θB between the wafer 100' and the line sensor 13, which is determined by: ##EQU4## wherein y2 or y3 is the edge position of a signal corresponding to a street when the line sensor 13 is positioned at x2 or x3, as shown in FIG. 15(A) or 15(B). Step 308 rotates the wafer 100' by correcting angle θB to complete the fine alignment.
After the completion of the fine alignment, a code, for example of SEMI standard, or a bar code, provided in the vicinity of the orientation flat 100a, is read by the line sensor 13 as shown in FIG. 17, while the wafer 100' is moved by the stage 7 in either direction indicated by the arrows, and the obtained information is used for wafer administration.
Subsequently there is searched a first chip which is to be subjected to inspection or further working.
At first, as shown in FIG. 18, the wafer 100' is moved to a position Pa at which the central portion of the wafer in the X-direction can be viewed by the line sensor 13. Then the wafer is stepwise moved, by one chip size at a time, in the negative-y-direction to find a position Pb where two streets 58 cannot be found simultaneously.
Then the wafer 100' is stepwise moved, by one chip size at a time, in the x-direction to find a position Pc where no street can be found. The first chip 59 is present at a position Pd which is in front of position Pc by one chip size. FIG. 19(A) shows the output signal of the line sensor 13 when it is located at the position Pc, and the wafer is so adjusted in position that the street 58 coincides with an original poing y 0 for alignment on the line sensor 13, as shown in FIG. 19(B).
The y-address of the stage 7 in this state becomes the original point on the y-axis for alignment. Subsequently the wafer 100' is moved, as shown in FIG. 20, from e to f where the line sensor is positioned on a street 58, whereby the output of the line sensor varies from a state shown in FIG. 21(A) to a state in FIG. 21 (B). The address x 0 of the x-axis of the stage in this state becomes the original point on the x-axis for alignment. The alignment procedure for the wafer 100' is thus completed.
Thereafter the chips on wafer 100' are subjected, on the stage 7, to wafer inspection and further working.
The foregoing explanation of fine alignment has been limited to the right-hand inspection unit, but similar procedure and structure are applicable also to the left-hand inspection unit. Also the alignment conducted on the stage 45 may also be achieved on the stage 7 or 5 and 15 or 17.
As shown in FIG. 22, the microcomputer 23a controls the function of the above-explained apparatus through an interface 84. There are also provided a driver 70 for driving the line sensor 13; and A/D converter 90 for A/D conversion of the output of line sensor 13; a driver 71 for driving the line sensor 53; and A/D converter 91 for A/D conversion of the output of line sensor 53; a driver 72 for driving a motor 15a for moving the X-Y stage 15 in the X-direction; a driver 73 for driving a motor 15b for moving the X-Y stage 15 in the Y-direction; a driver 74 for driving a motor 16a for moving the Z-stage 16 in the Z-direction; a driver 75 for driving a motor 17a for rotating the θ-rotation stage 17; a driver 76 for driving a motor 5a for moving the X-Y stage 5 in the X-direction; a driver 77 for driving a motor 5b for moving the X-Y stage 5 in the Y-direction; a driver 78 for driving a motor 6a for moving the Z-stage 6 in the Z-direction; a driver 79 for driving a motor 7a for rotating the θ-rotation stage 7; and drivers 80, 81, 82, 83 for respectively driving the motors 35, 39, 40, 44. The microcomputer 23a controls said drivers 70-83 through the interface 84 to cause the apparatus to function according to the flow charts shown in FIGS. 4, 11 and 16. | 4y
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DETAILED DESCRIPTION
This is a division of application Ser. No. 337,477 filed Feb. 28, 1973, now U.S. Pat. No. 3,856,798.
The present invention pertains to bicyclic derivatives of 1,4-dihydropyridine, to processes for their production and use and to pharmaceutical compositions containing such compounds and useful as antihypertensive agents and coronary vessel dilators.
In particular, the present invention pertains to compounds of the formula: ##SPC1##
Wherein
R 1 is hydrogen or lower alkyl;
Each of R 2 and R 4 , independent of the other, is lower alkyl of the group --OR', in which R' is a straight-chain, branched or cyclic, saturated or unsaturated, aliphatic hydrocarbyl or oxyhydrocarbyl, the carbon chain of which is optionally interrupted by one or two oxygen atoms;
R 3 is a saturated or unsaturated, straight-chain, branched or cyclic hydrocarbyl; aryl optionally carrying 1, 2 or 3 substituents selected from the group consisting of lower alkyl, lower alkoxy, azido, halogen, nitro, nitrile, trifluoromethyl, carbo(lower alkoxy), lower alkylsulfonyl, lower alkylsulfinyl or lower alkylthio; or a member selected from the group consisting of naphthyl, quinolyl, isoquinolyl, pyridyl, pyrimidyl, thienyl, furyl and pyrryl, said member optionally carrying a lower alkyl, lower alkoxy or halogeno substituent;
X is --CH 2 --, --NR 5 --in which R 5 is hydrogen or lower alkyl, --S--, or --O--; and
m is 2, 3 or 4.
A preferred class of the foregoing compounds are those of the formula: ##SPC2##
Wherein
X is --O--, --S--, --CH 2 -- or --NR 5 --;
m has a value of 2, 3 or 4;
R 1 is hydrogen or lower alkyl;
Each of R 2 and R 4 , independent of the other, is lower alkyl, lower alkoxy, lower alkoxy(lower alkoxy) or lower alkynyloxy preferably having 2 to 4 carbon atoms;
R 3 is lower alkyl, phenyl, phenyl substituted with from one to three substituents selected from the group consisting of lower alkyl, trifluoromethyl, cyano, halo, nitro and carbo(lower alkoxy); pyridyl; furyl; thienyl; or naphthyl; and
R 5 is hydrogen or lower alkyl.
The term lower alkyl denotes a univalent saturated branched or straight hydrocarbon chain containing from 1 to 6 carbon atoms. Representative of such lower alkyl groups are thus methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec.butyl, tert.butyl, pentyl, isopentyl, neopentyl, tert.pentyl, hexyl, and the like.
The term lower alkenyl denotes a univalent branched or straight hydrocarbon chain containing from 2 to 6 carbon atoms and nonterminal ethylenic unsaturation as, for example, vinyl, allyl, isopropenyl, 2-butenyl, 3-methyl-2-butenyl, 2-pentenyl, 3-pentenyl, 2-hexenyl, 4-hexenyl, and the like.
The term lower alkynyl denotes a univalent branched or straight hydrocarbon chain containing from 2 to 6 carbon atoms and nonterminal acetylenic unsaturation as, for example, ethynyl, 2-propynyl, 4-pentynyl, and the like.
The term lower alkoxy denotes a straight or branched hydrocarbon chain bound to the remainder of the molecule through an ethereal oxygen atom as, for example, methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, pentoxy and hexoxy.
The term lower alkylthio denotes a branched or straight hydrocarbon chain bound to the remainder of the molecule through a divalent sulfur as, for example, methylthio, ethylthio, propylthio, isopropylthio, butylthio, and the like.
The term halogen denotes the substituents fluoro, chloro, bromo and iodo.
As indicated, the present invention also pertains to the physiologically acceptable non-toxic acid addition salts of these basic compounds. Such salts include those derived from organic and inorganic acids such as, without limitation, hydrochloric acid, hydrobromic acid, phosphoric acid, sulfuric acid, methane sulphonic acid, acetic acid, tartaric acid, lactic acid, succinic acid, citric acid, malic acid, maleic acid, sorbic acid, aconitic acid, salicylic acid, phthalic acid, embonic acid, enanthic acid, and the like.
According to the present invention, the foregoing compounds are prepared by reacting a dicarbonyl compound of the formula: ##EQU1## wherein R 1 , R 2 and R 3 are as herein defined, with a cyclic enamino carbonyl compound of the formula: ##EQU2## in which R 4 , X and m are as herein defined. The condensation proceeds smoothly in good yields simply by heating the two components, generally in the presence of an inert organic solvent such as methanol, ethanol, propanol and similar alkanols, ethers such as dioxane and diethyl ether, glacial acetic acid, pyridine, dimethylformamide, dimethylsulfoxide, acetonitrile and the like. The reaction is conducted at temperatures of from 20° to 250°C, conveniently at the boiling point of the solvent, and while elevated pressure may be utilized, normal atmospheric pressure is generally satisfactory. The reactants are employed in substantially equimolar amounts. The dicarbonyl reagent can be utilized as such or generated in situ by the reaction of an aldehyde of the formula R 3 CHO and a β-dicarbonyl compound of the formula R 1 COCH 2 COR 2 .
Many of the dicarbonyl compounds utilized as one of the reactants are known to the art and the others can either be generated in situ as herein described or prepared according to methods well known to the art, see for example Org. Reaction XV, 204 et seq. (1967). Typical of this reactant are the following compounds:
benzylideneacetoacetic acid methyl ester,
ethylideneacetoacetic acid methyl ester,
isopropylideneacetoacetic acid methyl ester,
2-nitrobenzylideneacetoacetic acid methyl ester,
2-nitrobenzylideneacetylacetone,
benzylideneacetylacetone,
3-nitrobenzylideneacetoacetic acid methyl ester,
3-nitrobenzylideneacetoacetic acid propargyl ester,
3-nitrobenzylideneacetoacetic acid allyl ester,
3-nitrobenzylideneacetoacetic acid β-methoxyethyl ester,
3-nitrobenzylideneacetoacetic acid β-ethoxyethyl ester,
3-nitrobenzylideneacetoacetic acid isopropyl ester,
3-nitrobenzylideneacetylacetone,
4-nitrobenzylideneacetylacetone,
4-nitrobenzylideneacetoacetic acid β-propoxyethyl ester,
4-nitrobenzylideneacetoacetic acid n-propyl ester,
3-nitro-6-chlorobenzylideneacetoacetic acid methyl ester,
2-cyanobenzylideneacetoacetic acid methyl ester,
2-cyanobenzylideneacetoacetic acid methyl ester,
2-cyanobenzylideneacetoacetic acid ethyl ester,
2-cyanobenzylidenepropionylacetic acid ethyl ester,
3-cyanobenzylideneacetoacetic acid methyl ester,
3-nitro-4-chlorobenzylideneacetylacetone,
3-nitro-4-chlorobenzylideneacetoacetic acid t-butyl ester,
3-nitro-4-chlorobenzylideneacetoacetic acid methyl ester,
2-nitro-4-methoxybenzylideneacetoacetic acid methyl ester,
2-cyano-4-methylbenzylideneacetoacetic acid ethyl ester,
2-azidobenzylideneacetoacetic acid ethyl ester,
3-azidobenzylideneacetylacetone,
2-methylmercaptobenzylideneacetoacetic acid isopropyl ester,
2-sulphinylmethylbenzylideneacetoacetic acid ethyl ester,
2-sulphonylbenzylidenemethylacetoacetic acid allyl ester,
4-sulphonylmethylbenzylideneacetoacetic acid ethyl ester,
naphth-1-ylideneacetoacetic acid methyl ester,
naphth-1-ylideneacetoacetic acid ethyl ester,
naphth-2-ylideneacetoacetic acid ethyl ester,
2-ethoxynaphth-1-ylideneacetoacetic acid methyl ester,
2-methoxynaphth-1-ylideneacetoacetic acid ethyl ester,
5-bromonaphth-1-ylideneacetoacetic acid methyl ester,
quinol-2-ylmethylideneacetoacetic acid methyl ester,
quinol-3-ylmethylideneacetoacetic acid methyl ester,
quinol-4-ylmethylideneacetoacetic acid ethyl ester,
quinol-8-ylmethylideneacetoacetic acid ethyl ester,
isoquinol-1-ylmethylideneacetoacetic acid methyl ester,
isoquinol-3-ylmethylideneacetoacetic acid methyl ester,
α-pyridylmethylideneacetoacetic acid methyl ester,
α-pyridylmethylideneacetoacetic acid ethyl ester,
α-pyridylmethylideneacetoacetic acid allyl ester,
α-pyridylmethylideneacetoacetic acid cyclohexyl ester,
β-pyridylmethylideneacetoacetic acid β-methoxyethyl ester,
γ-pyridylmethylideneacetoacetic acid methyl ester,
6-methyl-α-pyridylmethylideneacetoacetic acid ethyl ester,
4,6-dimethoxypyrimid-5-ylmethylideneacetoacetic acid ethyl ester,
thien-2-ylmethylideneacetoacetic acid ethyl ester,
fur-2-ylmethylideneacetoacetic acid allyl ester,
pyrr-2-ylthylideneacetoacetic acid methyl ester,
nitrobenzylidenepropionylacetic acid ethyl ester,
α-pyridylmethylidenepropionylacetic acid ethyl ester,
α-pyridylmethylideneproionylacetic acid methyl ester,
α-pyridylmethylideneacetylacetone,
2-, 3- or 4-methoxybenzylideneacetoacetic acid ethyl ester,
2-, 3- or 4-methoxybenzylideneacetylacetone,
2-methoxybenzylideneacetoacetic acid allyl ester,
2-methoxybenzylideneacetoacetic acid allyl ester,
2-methoxybenzylideneacetoacetic acid propargyl ester,
2-methoxybenzylideneacetoacetic acid β-methoxyethyl ester,
2-isopropoxybenzylideneacetoacetic acid ethyl ester,
3-butoxybenzylideneacetoacetic acid methyl ester,
3,4,5-trimethoxybenzylidenacetoacetic acid allyl ester,
2-methylbenzylidenepropionylacetic acid methyl ester,
2-, 3- or 4-methylbenzylideneacetoacetic acid ethyl ester,
2-methylbenzylideneacetoacetic acid β-methoxyethyl ester,
2-methylbenzylideneacetoacetic acid β-propoxyethyl ester,
2-methylbenzylideneacetylacetone,
3,4-dimethoxy-5-bromobenzylideneacetoacetic acid ethyl ester,
2-, 3- or 4-chlorobenzylideneacetoacetic acid ethyl ester,
2-, 3- or 4-bromobenzylideneacetoacetic acid ethyl ester,
2-, 3- or 4-fluorobenzylideneactoacetic acid ethyl ester,
2-fluorobenzylideneacetoacetic acid methyl ester,
3-chlorobenzylideneacetylacetone,
3-chlorobenzylideneproionylacetic acid ethyl ester,
3-chlorobenzylideneactoacetic acid ethyl ester,
2-chlorobenzylideneacetoacetic acid allyl ester,
2-, 3- -or 4-trifluoromethylbenzylideneacetoacetic acid isopropyl ester,
3-trifluoromethylbenzylideneactoacetic acid methyl ester,
2-carbethoxybenzylideneacetoacetic acid ethyl ester,
3-carbomethoxybenzylideneacetoacetic acid methyl ester,
4-carboisopropoxybenzylideneacetoacetic acid isopropyl ester, and
4-carbomethoxybenzylideneacetoacetic acid allyl ester.
The cyclic enamino carbonyl reactants are similarly known or can be readily produced according to known methods, see for example Barnikow et al., Chem. Ber. 100, 1661 (1967). Typical of these reactants are the following:
2-carbethoxymethylidenepyrrolidine,
2-carbomethoxymethylidenepyrrolidine,
2-carbisopropoxymethylidenepyrrolidine,
2-carballyloxymethylidenepyrrolidine,
2-acetylmethylidenepyrrolidine,
2-carbethoxymethylidenepiperidine,
2-carbomethoxymethylidenepiperidine,
2-acetylmethylidenepiperidine,
2-acetylmethylidenehexahydroazepine,
2-carbethoxymethylidenehexahydrozepine,
2-carbomethoxymethylidenehexahydroazepine,
2-acetylmethylideneimidazolidine,
2-carbethoxymethylideneimidazolidine,
2-carbomethoxymethylideneimidazolidine,
2-carbethoxymethylidene-1-methylimidazolidine,
2-carbisopropoxymethylideneimidazolidine,
2-carballyloxymethylideneimidazolidine,
2-acetylmethylideneoxazolidine,
2-carbomethoxyideneoxazolidine,
2-carbethoxymethylideneoxyzolidine,
2-acetylmethylideneperhydro-1,3-oxazine,
2-carbethoxymethylideneperhydro-1,3-oxazine,
2-acetylmethylidenethiazolidine,
2-carbethoxymethylidenethiazolidine, and
2-carbethoxymethylideneperhydro11,3-thiazine.
In addition to these mentioned in the examples, the following are also important new compounds:
5-methyl-7-(2-nitrophenyl)-2,3,7-trihydrothiazolo-[1,2-a]pyridine-6,8-dicarboxylic acid dimethyl ester,
6-methyl-4-(2-nitrophenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid dimethyl ester, and
5-methyl-7-(2-nitrophenyl)-1,2,3,7-tetrahydroindolizine-6,8-dicarboxylic acid 6-methyl ester 8-ethyl ester.
As noted above, the compounds of the present invention demonstrate the ability to reduce blood pressure and to effect a dilation of the coronary vessels. They can accordingly be used where either or both of these effects are desired. Thus upon parenteral, oral or sublingual administration, the compounds produce a distinct and long lasting dilation of the coronary vessels which is intensified by a simultaneous nitrite-like effect of reducing the load on the heart. The effect on heart metabolism is thus one of energy saving. In addition, the compounds lower the blood pressure of normotonic and hypertonic animals and can thus be used as antihypertensive agents. These properties can be conveniently observed in well known laboratory models. Thus for example the coronary vessel dilation effect can be observed by measuring the increase in oxygen saturation in the coronary sinus in the narcotized, heart catherterized dog, as shown in the following table:
I.V. Dose Δ O.sub.2 % Return to normalCompounds (mg/kg) saturation O.sub.2 values (hours)__________________________________________________________________________5-methyl-7-(2-methyl- 2.0 22 10phenyl)-2,3,7-trihydro-thiazolo[1,2-a]-pyridine-6,8-dicarboxylicacid diethyl ester5-methyl-7-(2-cyano- 1.0 34 20phenyl)-2,3,7-trihydro-thiazolo[1,2-a]-pyridine-6,8-dicarboxy-lic acid diethyl ester5-methyl-7-(3-chloro- 2.0 27 20phenyl-2,3,7-trihydro-thiazolo[1,2-a]-pyridine-6,8-dicarboxy-lic acid diethyl ester5-methyl-7-(3-nitro- 5.0 30 90phenyl)-2,3,7-trihydro-thiazolo[1,2-a]-pyridine-6,8-dicarboxy-lic acid diethyl ester5-methyl-7-(2-cyano- 0.5 29 30phenyl)-2,3,7-trihydro-oxazolo[1,2-a]-pyridine-6,8-dicarboxy-lic acid diethyl ester5-methyl-7-(3-nitro- 2.0 21 >30phenyl)-2,3,7-trihydro-oxazolo[1,2-a] pyridine-6,8-dicarboxylic aciddiethyl ester5-methyl-7-(2-methyl- 5.0 20 60phenyl)-2,3,7-trihydro-oxazolo[1,2-a]-pyridine-6,8-dicarboxy-lic acid diethyl ester5-methyl-7-(3-chloro- 2.0 31 20phenyl)-2,3,7-trihydro-oxazolo[1,2-a]pyridine-6,8-dicarboxylic aciddiethyl ester5-methyl-7-(3-nitro- 5.0 47 45phenyl)-1,2,3,7-tetra-hydroimidazolo[1,2-a]-pyridine-6,8-dicarboxylicacid 6-(β-methoxyethyl)-ester 8-ethyl ester5-methyl-7-phenyl-1,2,3,7- 3.0 11 3tetrahydroimidazolo[1,2-a]-pyridine-6,8-dicarboxylicacid diethyl ester5-methyl-7-(3-nitro- 3.0 20 45phenyl)-1,2,3,7-tetra-hydroimidazolo[1,2-a]-pyridine-6,8-dicarboxylicacid diethyl ester5-methyl-7-(2-trifluoro- 2.0 13 >180methylphenyl)-1,2,3,7-tetra-hydroimidazolo[1,2-a]-pyridine-6,8-dicarboxylicacid diethyl ester5-methyl-7-(α-pyridyl)- 5.0 34 201,2,3,7-tetrahydro-imidazolo[1,2-a]pyridine-6,8-dicarboxylic aciddiethyl ester5-methyl-7-(2-nitro- 2.0 18 30phenyl)-1,2,3,7-tetra-hydroimidazolo[1,2-a]-pyridine-6,8-dicarboxylicacid 6-methyl ester 8-ethyl ester4,6-dimethyl-1,2-penta- 5.0 15 >60methylene-1,4-dihydro-pyridine-3,5-dicarboxylicacid 3-methyl ester 5-ethyl ester6-methyl-4-(3-nitrophenyl)- 2.0 28 >1801,2-pentamethylene-1,4-dihydropyridine-3,5-dicar-boxylic acid dimethyl ester6-methyl-4-(3-nitro- 0.5 22 150phenyl)-1,2-pentamethyl-ene-1,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester6-methyl-4-(3-nitro- 2.0 30 >180phenyl)-1,2-pentamethyl-ene-1,4-dihydropyridine-3,5-dicarboxylic acid 3-ethyl ester 5-methyl ester6-methyl-5-acetyl-4- 3.0 30 90(3-nitrophenyl)-1,2-pentamethylene-1,4-dihydro-pyridine-3-carboxylic acidethyl ester6-methyl-4-(2-cyano- 1.0 17 90phenyl)-1,2-pentamethyl-ene-1,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester6-methyl-4-(2-cyano- 1.0 21 >120phenyl)-1,2-pentamethyl-ene-1,4-dihydropyridine-3,5-dicarboxylic aciddiethyl ester6-methyl-4-(2-chloro- 5.0 34 120phenyl)-1,2-pentamethyl-ene-1,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester6-methyl-4-(2-methyl- 5.0 13 >90phenyl)-1,2-pentamethyl-ene-1,4-dihydropyridine-3,5-dicarboxylic acid3-methyl ester 5-ethyl ester6-methyl-4-(3-chloro- 3.0 30 150phenyl)-1,2-pentamethyl-ene-1,4-dihydropyridine-3,5-dicarboxylic aciddiethyl ester6-methyl-4-(2-trifluoro- 0.3 26 90methylphenyl)-1,2-penta-methylene-1,4-dihydro-pyridine-3,5-dicarboxylicacid 3-methyl ester 5-ethyl ester6-methyl-4-(2-trifluoro- 0.2 26 90methylphenyl)-1,2-penta-methylene-1,4-dihydro-pyridine-3,5-dicarboxylicacid diethyl ester5-methyl-7-(3-nitro- 3.0 20 3phenyl)-8-acetyl-1,2,3,7-tetrahydroindolizine-6-carboxylic acid ethylester5-methyl-7-(3-nitro- 2.0 16 90phenyl)-1,2,3,7-tetra-hydroindolizine-6,8-dicarboxylic acid 6-methyl ester 8-ethylester5-methyl-7-(2-methyl- 5.0 21 90phenyl)-1,2,3,7-tetra-hydroindolizine-6,8-dicarboxylic aciddiethyl ester6-methyl-8-(2-cyano- 0.5 23 >60phenyl)-1,2,3,4,8-penta-hydroquinolizine-7,9-dicarboxylic aciddiethyl ester5-methyl-6-acetyl-7- 2.0 30 20(3-nitrophenyl)-2,3,7-trihydrothiazolo[1,2-a]-pyridine-8-carboxylicacid ethyl ester5-methyl-7-(3-nitro- 5.0 35 >90phenyl)-1,2,3,7-tetra-hydroimidazolo[1,2-a]-pyridine-6,8-dicarboxy-lic acid 6-isopropylester 8-ethyl ester5-methyl-7-(3-nitro- 5.0 34 >30phenyl)-1,2,3,7-tetra-hydroimidazolo[1,2-a]-pyridine-6,8-dicarboxy-lic acid 6-propargylester 8-ethyl ester__________________________________________________________________________
The foregoing values do not necessarily correspond to the lowest dose at which a clearly detectable rise is observed in the oxygen saturation in the coronary sinus. Thus 6-methyl-4-(3-nitrophenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid, 6-methyl-4-(2-trifluoromethylphenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester-5-ethyl ester, and 6-methyl-4-(3-nitrophenyl)-1,2-pentamethylene-1,4-dihydropridine-3,5-dicarboxylic acid 3-ethyl ester-5-methyl ester produce such a rise at I.V. doses as low as 0.2, 0.3 and 0.5 mg/kg, respectively.
The hypotensive activity of the present compounds can be observed by measuring the blood pressure of hypertensive rats following peoral administration of the compounds. The following table demonstrates the dose which results in at least a 15 mm Hg reduction in blood pressure of such animals:
Dose Compound (mg/kg)______________________________________5-methyl-7-(2-cyanophenyl)-2,3,7-trihydrooxazolo- 1.0[1,2-a]pyridine-6,8-dicarboxylic acid diethylester5-methyl-7-(2-trifluoromethylphenyl)-1,2,3,7- 3.1tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester6-methyl-4-(3-nitrophenyl)-1,2-pentamethylene- 3.11,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester6-methyl-4-(3-nitrophenyl)-1,2-pentamethylene- 1.01,4-dihydropyridine-3,5-dicarboxylic acid 3-ethyl ester 5-methyl ester6-methyl-4-(2-cyanophenyl)-1,2-pentamethylene- 3.01,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester6-methyl-4-(2-trifluoromethylphenyl)-1,2-penta- 3.1methylene-1,4-dihydropyridine-3,5-dicarboxylicacid diethyl ester5-methyl-8-acetyl-7-(2-cyanophenyl)-1,2,3,7- 3.1tetrahydroindolizine-6-carboxylic acid ethylester6-methyl-8-(2-cyanophenyl)-1,2,3,4,8-pentahydro- 0.3quinolizine-7,9-dicarboxylic acid diethyl ester______________________________________
The toxicity of the compounds is remarkably low, as can be seen from the following toxicities measured in the mouse upon oral administration.
______________________________________ Dose Compound (mg/kg)______________________________________5-methyl-7-(2-trifluoromethylphenyl)-1,2,3,7- <3,000tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester6-methyl-4-(3-nitrophenyl)-1,2-pentamethylene- <3,0001,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester6-methyl-4-(3-nitrophenyl)-1,2-pentamethylene- <3,0001,4-dihydropyridine-3,5-dicarboxylic acid 3-ethyl ester 5-methyl ester6-methyl-4-(2-cyanophenyl)-1,2-pentamethylene- <3,0001,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester6-methyl-4-(2-trifluoromethylphenyl)-1,2-penta- <3,000methylene-1,4-dihydropyridine-3,5-dicarboxylicacid diethyl ester5-methyl-8-acetyl-7-(2-cyanophenyl)-1,2,3,7- <3,000tetrahydroindolizine-6-carboxylic acid ethylester______________________________________
In addition to the effect on blood pressure and coronary vessels, the compounds also lower the excitability of the stimulus formation and excitation conduction system within the heart so that an antifibrillation action is observed at therapeutic doses. The tone of the smooth muscle of the vessels is also greatly reduced. This vascular-spasmolytic action can be observed in the entire vascular system as well as in more or less isolated and circumscribed vascular regions such as the central nervous system. In addition, a strong muscular-spasmolytic action is manifested in the smooth muscle of the stomach, the intestinal tract, the urogenital tract and the respiratory system. Finally, there is some evidence that the compounds influence the cholesterol level and lipid level of the blood. These effects complement one another and the compounds are thus highly desirable as pharmaceutical agents to be used in the treatment of hypertension and conditions characterized by a constriction of the coronary blood vessels.
Pharmaceutical compositions for effecting such treatment will contain a major or minor amount, e.g. from 95 to 0.5%, of at least one 1,4-dihydropyridine as herein defined in combination with a pharmaceutical carrier, the carrier comprising one or more solid, semi-solid or liquid diluent, filler and formulation adjuvant which is non-toxic, inert and pharmaceutically acceptable. Such pharmaceutical compositions are preferably in dosage unit form; i.e. physically discrete units containing a predetermined amount of the drug corresponding to a fraction or multiple of the dose which is calculated to produce the desired therapeutic response. The dosage units can contain one, two, three, four or more single doses or, alternatively, one-half, third or fourth of a single dose. A single dose preferably contains an amount sufficient to produce the desired therapeutic effect upon administration of one application of one or more dosage units according to a predetermined dosage regimen, usually a whole, half, third or quarter of the daily dosage administred once, twice, three or four times a day. Other therapeutic agents can also be present.
Although the dosage and dosage regimen must in each case be carefully adjusted, utilizing sound professional judgement and considering the age, weight and condition of the recipient, the route of administration and the nature and gravity of the illness, generally the daily dose will be from about 0.05 to about 10 mg/kg, preferably 0.1 to 5.0 mg/kg, when administered parenterally and from about 1 to about 100 mg/kg, preferably 5 to 50 mg/kg, when administered orally. In some instances a sufficient therapeutic effect can be obtained at lower doses while in others, larger doses will be required.
Oral administration can be effected utilizing solid and liquid dosage unit forms such as powders, tablets, dragees, capsules, granulates, suspensions, solutions and the like.
Powders are prepared by comminuting the compound to a suitable fine size and mixing with a similarly comminuted pharmaceutical carrier such as an edible carbohydrate as for example starch, lactose, sucrose, glucose or mannitol. Sweetening, flavoring, preservative, dispersing and coloring agents can also be present.
Capsules are made by preparing a powder mixture as described above and filling formed gelatin sheaths. Glidants and lubricants such as colloidal silica, talc, magnesium stearate, calcium stearate or solid polyethylene glycol can be added to the powder mixture before the filling operation. A disintegrating or solubilizing agent such as agar-agar, calcium carbonate or sodium carbonate can also be added to imprve the availability of the medicament when the capsule is ingested.
Tablets are formulated for example by preparing a powder mixture, granulating or slugging, adding a lubricant and disintegrant and pressing into tablets. A powder mixture is prepared by mixing the compound, suitably comminuted, with a diluent or base as described above, and optionally with a binder such as carboxymethyl cellulose, an alginate, gelatin, or polyvinyl pyrrolidone, a solution retardant such as paraffin, a resorption accelerator such as a quaternary salt and/or an absorption agent such as bentonite, kaolin or dicalcium phosphate. The powder mixture can be granulated by wetting with a binder such as syrup, starch paste, acacia mucilage or solutions of cellulosic or polymeric materials and forcing through a screen. As an alternative to granulating, the powder mixture can be run through the tablet machine and the resulting imperfectly formed slugs broken into granules. The granules can be lubricated to prevent sticking to the tablet forming dies by means of the addition of stearic acid, a stearate salt, talc or mineral oil. The lubricated mixture is then compressed into tablets. The midicaments can also be combined with free flowing inert carriers and compressed into tablets directly without going through the granulating or slugging steps. A clear or opaque protective coating consisting of a sealing coat of shellac, a coating of sugar or polymeric material and a polish coating of wax can be provided. Dyestuffs can be added to these coatings to distinguish different unit dosages.
Oral fluids such as solutions, syrups and elixirs can be prepared in dosage unit form so that a given quantity contains a predetermined amount of the compound. Syrups can be prepared by dissolving the compound in a suitably flavored aqueous sucrose solution while elixirs are prepared through the use of a nontoxic alcoholic vehicle. Suspensions can be formulated by dispersing the compound in a nontoxic vehicle. Solubilizers and emulsifiers such as ethoxylated isostearyl alcohols and polyoxyethylene sorbitol esters, preservatives, flavor additives such as peppermint oil or saccharin, and the like can also be added.
Where appropriate, dosage unit formulations for oral administration can be microencapsulated. The formulation can also be prepared to prolong or sustain the release as for example by coating or embedding particulate material in polymers, wax or the like.
Parenteral administration can be effected utilizing liquid dosage unit forms such as sterile solutions and suspensions intended for subcutaneous, intramuscular or intravenous injection. There are prepared by suspending or dissolving a measured amount of the compound in a nontoxic liquid vehicle suitable for injection such as an aqueous or oleaginous medium and sterilizing the suspension or solution. Alternatively a measured amount of the compound is placed in a vial and the vial and its contents are sterilized and sealed. An accompanying vial or vehicle can be provided for mixing prior to administration. Nontoxic salts and salt solutions can be added to render the injection isotonic. Stabilizers, preservatives and emulsifiers can also be added.
The following examples will serve to further typify the nature of the present invention through the presentation of specific embodiments. These examples should not be construed as a limitation on the scope of the invention since the subject matter regarded as the invention is set forth in the appended claims.
EXAMPLE 1 ##SPC3##
Upon boiling a solution of 9.5 g of 2 -trifluoromethylbenzylideneacetoacetic acid ethyl ester and 6.2 g of 2-carbethoxymethylidenethiazolidine in 60 ml of ethanol for 8 hours, 5-methyl-7-(2-trifluoromethylphenyl)-2,3,7-trihydrothiazolo[1,2-a]-pyridine-6,8-dicarboxylic acid diethyl ester of melting point 107° (ethyl acetate/petroleum ether) is obtained.
Yield: 57% of theory.
EXAMPLE 2 ##SPC4##
Upon heating a solution of 7.8 of 2-methylbenzylideneacetoacetic acid ethyl ester and 5,8 g. of 2-carbethoxymethylidenethiazolidine in 50 ml of isopropanol for 10 hours, 5-methyl-7-(2-methylphenyl)-2,3,7-trihydrothiazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 158° (alcohol) is obtained.
Yield: 66% of theory.
EXAMPLE 3 ##SPC5##
Heating a solution of 8.1 g. of 2-cyanobenzylideneacetoacetic acid ethyl ester and 5.7 g of 2-carbethoxymethylidenethiazolidine in 60 ml of ethanol for 6 hours yields 5-methyl-7-(2-cyanophenyl)-2,3,7-trihydrothiazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 206° (ethanol).
Yield: 84% of theory.
EXAMPLE 4 ##SPC6##
Upon heating a solution of 8.4 g of 3-chlorobenzylideneacetic acid ethyl ester and 5.7 g of 2-carbethoxymethylidenethiazolidine in 50 ml of ethanol for 6 hours, 5-methyl-7-(3-chlorophenyl)-2,3,7-trihydrothiazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 109° (ethyl acetate/petroleum ether) is obtained.
Yield: 71% of theory.
EXAMPLE 5 ##SPC7##
Boiling a solution of 8.8 g of 3-nitrobenzylideneacetoacetic acid ethyl ester and 5.7 g of 2-carbethoxymethylidenethiazolidine in 50 ml of ethanol for 6 hours yields 5-methyl-7-(3-nitrophenyl)-2,3,7-trihydrothiazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 143° (ethanol).
Yield: 68% of theory.
EXAMPLE 6 ##SPC8##
Heating a solution of 8.1 g of 2-cyanobenzylidineacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneoxazolidine in 50 ml of ethanol for 8 hours yields 5-methyl-7-(2-cyanophenyl)-2,3,7-trihydrooxazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 199°(alcohol).
Yield: 51% of theory.
EXAMPLE 7 ##SPC9##
Upon boiling a solution of 8.8 g of 3-nitrobenzylideneacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneoxazolidine in 60 ml of glacial acetic acid for 6 hours, 5-methyl-7-(3-nitrophenyl)-2,3,7-trihydrooxazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 179° (ethanol) is obtained.
Yield: 62% of theory.
EXAMPLE 8 ##SPC10##
Upon heating a solution of 7.7 g of 2-methylbenzylideneacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneoxazolidine in 50 ml of ethanol for 8 hours, 5-methyl-7-(2-methylphenyl)-2,3,7-trihydrooxazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 145° (ethyl acetate/petroleum ether) is obtained.
Yield: 59% of theory.
EXAMPLE 9 ##SPC11##
Boiling a solution of 8.4 g of 3-chlorobenzylideneacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneoxazolidine in 50 ml of glacial acetic acid for 8 hours yields 5-methyl-7-(3-chlorophenyl)-2,3,7-trihydrooxazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 110° (ethyl acetate/petroleum ether).
Yield: 66% of theory.
EXAMPLE 10 ##SPC12##
Upon heating a solution of 6 g of ethylideneacetoacetic acid ethyl ester and 6 g of 2-carbethoxymethylideneimidazolidine in 50 ml of ethanol for 10 hours, 5,7-dimethyl-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 138° (ethanol) is obtained.
Yield: 58% of theory.
EXAMPLE 11 ##SPC13##
Upon heating a solution of 9.8 g of 3-nitrobenzylideneacetoacetic acid β-methoxyethyl ester and 5.2 g of 2 -carbethoxymethylideneimidazolidine in 60 ml of alcohol for 6 hours, 5-methyl-7-(3-nitrophenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid 6-(β-methoxyethyl) ester 8-ethyl ester of melting point 126°-127° (alcohol) is obtained.
Yield: 63% of theory.
EXAMPLE 12 ##SPC14##
Upon heating a solution of 5.3 g of benzaldehyde, 6.5 g of acetoacetic acid ethyl ester and 7.8 g of 2-carbethoxymethylideneimidazolidine in 50 ml of ethanol for 6 hours, 5-methyl-7-phenyl-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 165° (alcohol) is obtained.
Yield: 81% of theory.
EXAMPLE 13 ##SPC15##
Heating a solution of 8.8 g of 3-nitrobenzylideneacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 50 ml of alcohol for 6 hours yields 5-methyl-7-(3-nitrophenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine6,8-dicarboxylic acid diethyl ester of melting point 159°-60° (alcohol/dimethylformamide).
Yield: 68% of theory.
EXAMPLE 14 ##SPC16##
Boiling a solution of 7.8 g of 3-nitrobenzylideneacetylacetone and 5.2 g of 2-carbethoxymethylideneimidazolidine in 50 ml of glacial acetic acid for 6 hours yields 5-methyl-6-acetyl-7-(3-nitrophenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-8-carboxylic acid ethyl ester of melting point 155° (ethanol).
Yield: 54% of theory.
EXAMPLE 15 ##SPC17##
Upon heating a solution of 9.5 g of 2-trifluoromethylbenzylideneacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 50 ml of ethanol for 6 hours, 5-methyl7-(2-trifluoromethylphenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 137° (alcohol) is obtained.
Yield: 63% of theory.
EXAMPLE 16 ##SPC18##
Boiling a solution of 7.7 g of 2-methylbenzylideneacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 50 ml of ethanol for 10 hours yields 5-methyl-7-(2-methylphenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 202° (alcohol).
Yield: 69% of theory.
EXAMPLE 17 ##SPC19##
Boiling a solution of 8.4 g of 2-chlorobenzylideneacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 50 ml of ethanol for 8 hours yields 5-methyl-7-(2-chlorophenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 198% (alcohol).
Yield: 59% of theory.
EXAMPLE 18 ##SPC20##
Upon heating a solution of 8.4 g of 3-chlorobenzylideneacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 50 ml of ethanol for 8 hours, 5-methyl-7-(3-chlorophenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8dicarboxylic acid diethyl ester of melting point 137° (alcohol) is obtained.
Yield: 60% of theory.
EXAMPLE 19 ##SPC21##
Boiling a solution of 6.9 g of 2-furfurylideneacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 50 ml of ethanol for 8 hours yields 5-methyl-7-(2-furyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 164° (ethanol).
Yield: 65% of theory.
EXAMPLE 20 ##SPC22##
Upon heating a solution of 5.4 g of pyridin-2-aldehyde, 6.5 g of acetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 50 ml of ethanol for 6 hours, 5-methyl-7-(α-pyridyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 191° (isopropanol) is obtained.
Yield: 46% of theory.
EXAMPLE 21 ##SPC23##
Boiling a solution of 8.7 g of 3-nitrobenzylideneacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylidene-1-methylimidazolidine in 50 ml of alcohol for 6 hours yields 1,5-dimethyl-7-(3-nitrophenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester (oil).
Yield: 69% of theory.
EXAMPLE 22 ##SPC24##
Upon heating a solution of 7.1 g of 3-nitro-6-chlorobenzylideneacetoacetic acid methyl ester and 3.9 g of 2-carbethoxymethylideneimidazolidine in 50 ml of ethanol for 8 hours, 5-methyl-7-(3-nitro-6-chlorophenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid 6-methyl ester 8-ethyl ester of melting point 182° (alcohol) is obtained.
Yield: 75% of theory.
EXAMPLE 23 ##SPC25##
Upon boiling a solution of 8.3 g of 2-nitrobenzylideneacetoacetic acid methyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 50 ml of ethanol for 6 hours, 5-methyl-7-(2-nitrophenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid 6-methyl ester 8-ethyl ester of melting point 185° is obtained.
EXAMPLE 24 ##SPC26##
Upon boiling a solution of 7.8 g of ethylideneacetoacetic acid ethyl ester and 8.5 g of 2-carbomethoxymethylidenehexahydroazepine in 50 ml of alcohol for 6 hours, 4,6-dimethyl-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester of melting point 70° (ethyl acetate/petroleum) is obtained.
Yield: 57% of theory.
EXAMPLE 25 ##SPC27##
Upon boiling a solution of 8.3 g of 3-nitrobenzylideneacetoacetic acid methyl ester and 5.7 g of 2-carbomethoxymethylidenehexahydroazepine in 50 ml of glacial acetic acid for 8 hours, 6-methyl-4-(3-nitrophenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid dimethyl ester of melting point 98° (ethyl acetate/petroleum ether) is obtained.
Yield: 68% of theory.
EXAMPLE 26 ##SPC28##
Heating a solution of 8.8 g of 3-nitrobenzylideneacetoacetic acid ethyl ester and 5.6 g of 2-carbomethoxymethylidenehexahydroazepine in 50 ml of ethanol for 6 hours yields 6-methyl-4-(3-nitrophenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester of melting point 75° (ethyl acetate/petroleum ether).
Yield: 56% of theory.
EXAMPLE 27 ##SPC29##
After boiling a solution of 8.3 g of 3-nitrobenzylideneacetoacetic acid methyl ester and 6.1 g of 2-carbethoxymethylidenehexahydroazepine in 50 ml of alcohol for 8 hours, 6-methyl-4-(3-nitrophenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid 3-ethyl ester 5-methyl ester of melting point 85°C (ethyl acetate/petroleum ether) is obtained.
Yield: 62% of theory.
EXAMPLE 28 ##SPC30##
Upon heating a solution of 7.6 g of 3-nitrobenzaldehyde, 5.0 g of acetylacetone and 9.1 g of 2-carbethoxymethylidenehexahydroazepine in 50 ml of ethanol for 8 hours, 6-methyl-5-acetyl-4-(3-nitrophenyl)-1,2-pentamethylene-1,4-dihydropyridine-3-carboxylic acid ethyl ester of melting point 91° (alcohol/water) is obtained.
Yield: 48% of theory.
EXAMPLE 29 ##SPC31##
Upon boiling a solution of 8.1 g of 2-cyanobenzylideneacetoacetic acid ethyl ester and 5.6 g of 2-carbomethoxymethylidenehexahydroazepine in 50 ml of ethanol for 8 hours, 6-methyl-4-(2-cyanophenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester of melting point 154° (alcohol) is obtained.
Yield: 61% of theory.
EXAMPLE 30 ##SPC32##
Boiling a solution of 8.1 g of 2-cyanobenzylideneacetoacetic acid ethyl ester and 6.1 g of 2-carbethoxymethylidenehexahydroazepine in 50 ml of ethanol for 6 hours yields 6-methyl-4-(2-cyanophenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid diethyl ester of melting point 134° (ethyl acetate/petroleum ether).
Yield: 54% of theory.
EXAMPLE 31 ##SPC33##
Upon boiling a solution of 8.4 g of 2-chlorobenzylideneacetoacetic acid ethyl ester and 5.6 g of 2-carbomethoxymethylidenehexahydroazepine in 50 ml of ethanol for 6 hours, 6-methyl-4-(2-chlorophenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester of melting point 123° (ethanol) is obtained.
Yield: 50% of theory.
EXAMPLE 32 ##SPC34##
Upon heating a solution of 7.7 g of 2-methylbenzylideneacetoacetic acid ethyl ester and 5.6 g of 2-carbomethoxymethylidenehexahydroazepine in 50 ml of ethanol for 8 hours, 6-methyl-4-(2-methylphenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester of melting point 130° (alcohol) is obtained.
Yield: 74% of theory.
EXAMPLE 33 ##SPC35##
Boiling a solution of 8.4 g of 3-chlorobenzylideneacetoacetic acid ethyl ester and 6.1 g of 2-carbethoxymethylidenehexahydroazepine in 50 ml of glacial acetic acid for 6 hours yields 6-methyl-4-(3-chlorophenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid diethyl ester of melting point 100° (ethyl acetate/petroleum ether).
Yield: 65% of theory.
EXAMPLE 34 ##SPC36##
After boiling a solution of 9.1 g of 2-trifluoromethylbenzylideneacetoacetic acid ethyl ester and 5.6 g of 2-carbomethoxymethylidenehexahydroazepine in 50 ml of ethanol for 8 hours, 6-methyl-4-(2-trifluoromethylphenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid 3-methyl ester 5-ethyl ester of melting point 111° (ethyl acetate/petroleum ether) is obtained.
Yield: 76% of theory.
EXAMPLE 35 ##SPC37##
Heating a solution of 9.1 g of 2-trifluoromethylbenzylideneacetoacetic acid ethyl ester and 6.1 g of 2-carbethoxymethylidenehexahydroazepine in 50 ml of ethanol for 10 hours yields 6-methyl-4-(2-trifluoromethylphenyl)-1,2-pentamethylene-1,4-dihydropyridine-3,5-dicarboxylic acid diethyl ester of melting point 104° (alcohol/water).
Yield: 71% of theory.
EXAMPLE 36 ##SPC38##
Boiling a solution of 8.8 g of 3-nitrobenzylideneacetoacetic acid ethyl ester and 4.6 g of 2 -acetylmethylidenepyrrolidine in 50 ml of ethanol for 6 hours yields 5-methyl-7-(3-nitrophenyl)-8-acetyl-1,2,3,7-tetrahydroindolizine-6-carboxylic acid ethyl ester of melting point 161° (isopropanol).
Yield: 72% of theory.
EXAMPLE 37 ##SPC39##
Upon heating a solution of 9.4 g of 2-trifluoromethylbenzylideneacetoacetic acid ethyl ester and 4.6 g of 2-acetylmethylidenepyrrolidine in 50 ml of glacial acetic acid for 8 hours, 5-methyl-8-acetyl-7-(2-trifluoromethylphenyl)-1,2,3,7-tetrahydroindolizine-6-carboxylic acid ethyl ester of melting point 126° (ethyl acetate/petroleum ether) is obtained.
Yield: 49% of theory.
EXAMPLE 38 ##SPC40##
Upon boiling a solution of 8.1 g of 2-cyanobenzylideneacetoacetic acid ethyl ester and 4.6 g of acetylmethylidenepyrrolidine in 50 ml of ethanol for 6 hours, 5-methyl-8-acetyl-7-(2-cyanophenyl)-1,2,3,7-tetrahydroindolizine-6-carboxylic acid ethyl ester of melting point 167° (ethanol) is obtained.
Yield: 59% of theory.
EXAMPLE 39 ##SPC41##
Upon boiling a solution of 8.3 g of 3-nitrobenzylideneacetoacetic acid methyl ester and 5.6 g of 2-carbethoxymethylidenepyrrolidine in 50 ml of glacial acetic acid for 8 hours, 5-methyl-7-(3-nitrophenyl)-1,2,3,7-tetrahydroindolizine-6,8-dicarboxylic acid 6-methyl ester 8-ethyl ester of melting point 120° (ethanol) is obtained.
Yield: 73% of theory.
EXAMPLE 40 ##SPC42##
Upon boiling a solution of 7.7 g of 2-methylbenzylideneacetoacetic acid ethyl ester and 5.6 g of carbethoxymethylidenepyrrolidine in 50 ml of ethanol for 8 hours, 5-methyl-7-(2-methylphenyl)-1,2,3,7-tetrahydroindolizine-6,8-dicarboxylic acid diethyl ester of melting point 148° (alcohol) is obtained.
Yield: 62% of theory.
EXAMPLE 41 ##SPC43##
Upon heating a solution of 8.1 g of 2-cyanobenzylideneacetoacetic acid ethyl ester and 5.6 g of 2-carbethoxymethylidenepiperidine in 50 ml of ethanol for 6 hours, 6-methyl-8-(2-cyanophenyl)-1,2,3,4,8-pentahydroquinolizine-7,9-dicarboxylic acid diethyl ester of melting point 142° (ethyl acetate/petroleum ether) is obtained.
Yield: 59% of theory.
EXAMPLE 42 ##SPC44##
Boiling a solution of 7.7 g of 2-methylbenzylideneacetoacetic acid ethyl ester and 5.6 g of 2-carbethoxymethylidenepiperidine in 50 ml of ethanol for 12 hours yields 6-methyl-8-(2-methylphenyl)-1,2,3,4,8-pentahydroquinolizine-7,9-dicarboxylic acid diethyl ester of melting point 106° (ethyl acetate/petroleum ether).
Yield: 75% of theory.
EXAMPLE 43 ##SPC45##
Upon boiling a solution of 7.8 g of 3-nitrobenzylideneacetylacetone and 5.7 g of 2-carbethoxymethylidenethiazolidine in 60 ml of ethanol for 7 hours, 5-methyl-6-acetyl-7-(3-nitrophenyl)-2,3,7-trihydrothiazolo[1,2-a]pyridine-8-carboxylic acid ethyl ester of melting point 152° (ethyl acetate/petroleum ether) is obtained.
Yield: 59% of theory.
EXAMPLE 44 ##SPC46##
Boiling a solution of 9.2 g of 3-nitrobenzylideneacetoacetic acid isopropyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 60 ml of ethanol for 2 hours yields 5-methyl-7-(3-nitrophenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid 6-isopropyl ester 8-ethyl ester of melting point 136° (ethanol).
Yield: 65% of theory.
EXAMPLE 45 ##SPC47##
Heating a solution of 9.1 g of 3-nitrobenzylideneacetoacetic acid propargyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 60 ml of ethanol for 6 hours yields 5-methyl-7-(3-nitrophenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid 6-propargyl ester 8-ethyl ester of melting point 153° (ethanol).
Yield: 54% of theory.
EXAMPLE 46 ##SPC48##
Heating a solution of 9.7 g of 3-carbethoxybenzylideneacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 60 ml of ethanol for 6 hours yields 5-methyl-7-(3-carbethoxyphenyl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 149°C (ethanol).
Yield: 69% of theory.
EXAMPLE 47 ##SPC49##
Boiling a solution of 7.4 g of then-2-ylideneacetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 60 ml of ethanol for 6 hours yields 5-methyl-7-(then-2-yl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 134°C (ethanol).
Yield: 72% of theory.
EXAMPLE 48 ##SPC50##
Heating a solution of 9.0 g of (naphth-1-ylidene)acetoacetic acid ethyl ester and 5.2 g of 2-carbethoxymethylideneimidazolidine in 60 ml of ethanol for 6 hours yields 5-methyl-7-(naphth-1-yl)-1,2,3,7-tetrahydroimidazolo[1,2-a]pyridine-6,8-dicarboxylic acid diethyl ester of melting point 169°-170°C (ethanol).
Yield: 52% of theory. | 4y
|
FIELD OF THE INVENTION AND RELATED ART STATEMENT
This invention relates to a gas-liquid contact apparatus for use in wet flue gas desulfurizers and the like wherein one or more header pipes having attached thereto a plurality of spray nozzles for spouting a slurry upward are disposed in the main body of a tower through which a gas flows, and the header pipes are made of a fiber-reinforced resin composite material having improved corrosion resistance and wear resistance.
In recent years, wet flue gas desulfurizers wherein sulfur dioxide present in flue gas is removed by absorption into an absorbent slurry have become widely popular. In this type of desulfurizers, it is important to bring flue gas into efficient contact with an absorbent slurry. Accordingly, the present applicant has previously proposed a flue gas desulfurizer constructed so that a slurry is spouted upward in the main body of a tower through which a gas flows and hence capable of achieving an improvement in gas-liquid contact efficiency, a reduction in required volume, and a simplification of construction (see Japanese Utility Model Provisional Publication No. 59-53828/'84). FIG. 3 illustrates an essential part of an exemplary flue gas desulfurizer using a gas-liquid contact apparatus of such construction.
This flue gas desulfurizer is equipped with a tank 2 formed at the bottom of an absorption tower 1 and supplied with an absorbent slurry S containing, for example, limestone by means of a slurry feeding system; a circulating pump 4 for feeding absorbent slurry S within tank 2 to a main tower body 3 formed in the-upper part of absorption tower 1 and bringing it into contact with flue gas; and a stirring rod 7 supported on the top plate of tank 2 through the medium of a rotating shaft 5, and rotated horizontally in absorbent slurry S within tank 2 by means of a motor 6. Moreover, ducts 8 and 9 serving as an inlet and an outlet for flue gas are installed at the top of main tower body 3 and at the top of a lateral part of tank 2, respectively, so that flue gas flows through main tower body 3 and over the surface of absorbent slurry S within tank 2.
Moreover, one or more header pipes 10 are disposed in main tower body 3 and connected to the delivery side of circulating pump 4. To each of these header pipes 10 are attached a plurality of spray nozzles 11 for spouting absorbent slurry S upward in the form of liquid columns. Thus, a gas-liquid contact apparatus for bringing flue gas into efficient contact with absorbent slurry S is constructed. In the above-described desulfurizer, the gas-liquid contact apparatus is usually equipped with a plurality of header pipes 10.
When used under relatively mild environmental conditions, for example, under such conditions that the liquid column height of absorbent slurry S is not greater than 1 m and the gypsum concentration in absorbent slurry S is not greater than 15% by weight, header pipes 10 have conventionally been made of a fiber-reinforced resin composite material (hereinafter referred to simply as FRP) such as common glass fiber-reinforced polyester resin, or a material comprising resin-lined carbon steel with exclusive consideration for corrosion resistance. However, under severe conditions which cause the liquid column height of absorbent slurry S and/or the gypsum concentration in absorbent slurry S to exceed the aforesaid limit, it has been common practice to use metallic materials (e.g., stainless steel and Hastelloy) having high hardness and exhibiting excellent wear resistance and corrosion resistance.
In this flue gas desulfurizer, untreated flue gas is introduced, for example, through duct 8, and brought into contact with absorbent slurry S fed by means of circulating pump 4 and spouted from spray nozzles 11, so that sulfur dioxide present in the untreated flue gas is removed by absorption into absorbent slurry S. The resulting flue gas is discharged through duct 9 as the treated flue gas. Absorbent slurry S spouted from spray nozzles 11 flows downward while absorbing sulfur dioxide, and enters tank 2 where it is oxidized by contact with a large number of air bubbles produced from air introduced into absorbent slurry S within tank 2 by an air supply (not shown) while being stirred with stirring rod 7. Thus, gypsum is formed as a by-product and withdrawn from the system.
During this process, absorbent slurry S is spouted upward from spray nozzles 11 in the form of liquid columns. The spouted absorbent slurry S scatters at its peaks and then falls, so that the falling absorbent slurry S and the spouted absorbent slurry S collide with each other to produce fine droplets. Thus, as compared with absorption towers of the packed tower type and the like, this apparatus shows an increase in gas-liquid contact area per unit volume in spite of its simple construction.
Moreover, since flue gas is effectively dragged into the spouted streams of absorbent slurry S in the neighborhood of nozzles 11, absorbent slurry S and the flue gas are effectively mixed. This effect also serves to enhance gas-liquid contact efficiency, so that even small-volume and simple absorption tower 1 can purify flue gas with a high degree of desulfurization. Furthermore, gas-liquid contact efficiency and hence the degree of desulfurization can be effectively varied by controlling the delivery pressure of circulating pump 4 or other parameter to alter the liquid column height of absorbent slurry S spouted from spray nozzles 11.
In the above-described conventional gas-liquid contact apparatus, under such conditions that the liquid column height of the absorbent slurry is unduly large, the gypsum concentration in the absorbent slurry is unduly high, and/or the circulation-rate of the absorbent slurry is so high as to give a high liquid flow velocity in header pipes 10, header pipes 10 need to be made of an expensive corrosion-resistant and wear-resistant material in order to prevent a decrease in reliability due to wear as well as corrosion. This disadvantageously causes an increase in material, manufacturing or processing cost and further in installation cost, resulting in reduced economical efficiency. More specifically, in cases where the liquid column height of absorbent slurry S is greater than 1 m, the gypsum concentration in absorbent slurry S is greater than 15% by weight, and/or the liquid flow velocity in header pipes 10 is greater than 2 m/sec, an expensive metallic material having high hardness and exhibiting excellent wear resistance has conventionally been used for header pipes 10, thus requiring considerable material, manufacturing and processing costs. Furthermore, in cases where corrosion resistance is desired under especially severe conditions, the reduction in economical efficiency become more marked because of the necessity of using a nickel alloy.
OBJECT AND SUMMARY OF THE INVENTION
In view of the above-described existing state of the art, an object of the present invention is to provide a gas-liquid contact apparatus which is equipped with lightweight and inexpensive header pipes having excellent wear resistance and corrosion resistance and hence exhibits high reliability and economical efficiency.
In order to accomplish the above object, the present invention provides:
(1) a gas-liquid contact apparatus wherein one or more header pipes having attached thereto a plurality of spray nozzles for spouting a slurry upward are disposed in the main body of a tower through which a gas flows, characterized in that the header pipes are made of a fiber-reinforced resin composite material and the outer surface thereof is formed of a corrosion-resistant and wear-resistant layer of a resin containing 5 to 90% by weight of ceramic particles; and
(2) a gas-liquid contact apparatus wherein one or more header pipes having attached thereto a plurality of spray nozzles for spouting a slurry upward are disposed in the main body of a tower through which a gas flows, characterized in that the header pipes are made of a fiber-reinforced resin composite material and the outer and inner surfaces thereof are formed of a corrosion-resistant and wear-resistant layer of a resin containing 5 to 90% by weight and 1 to 70% by weight, respectively, of ceramic particles.
According to the present invention, a corrosion-resistant and wear-resistant layer is formed on the outer surface, or the outer and inner surfaces, of header pipes, so that wear of the outer surface of the header pipes due to the falling and impingement-of an upwardly spouted slurry and/or wear of the inner surface of the header pipes due to friction caused by the flow of the slurry can be reduced. Consequently, the present invention makes it possible to secure wear resistance, using inexpensive and lightweight FRP with high impact resistance as a main body of a header pipe, and improves the economical efficiency and reliability of the gas-liquid contact apparatus and hence the desulfurizer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional side view illustrating an essential part of a gas-liquid contact apparatus in accordance with one embodiment of the present invention;
FIG. 2 is a sectional side view illustrating an essential part of a gas-liquid contact apparatus in accordance with another embodiment of the present invention; and
FIG. 3 is a schematic view illustrating an essential part of a conventional flue gas desulfurizer to which the gas-liquid contact apparatus of the present invention can be applied.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the apparatus of the present invention, the header pipes are made of FRP and the outer surface thereof is formed of a corrosion-resistant and wear-resistant layer of a resin containing 5 to 90% by weight of ceramic particles, in order to reduce wear caused when the spouted absorbent slurry falls and impinges against the header pipes. Consequently, wear caused by the falling absorbent slurry can be reduced even under such conditions that the liquid column height of the spouted slurry is not less than 1 m.
Moreover, where a highly corrosive and wearing environment is created e.g., where the flow velocity of the absorbent slurry fed to the header pipes is high or where the concentration of particles (such as gypsum) in the absorbent slurry is high!, the inner surface of the header pipes, in addition to the outer surface thereof, is formed of a corrosion-resistant and wear-resistant layer of a resin containing 1 to 70% by weight of ceramic particles. Thus, wear caused when the absorbent slurry impinges against the inner surface of the header pipes can be markedly reduced even under such conditions that the flow velocity of the absorbent slurry fed to the header pipes is greater than 2 m/sec and/or the gypsum concentration in the absorbent slurry is greater than 15% by weight.
Referring to FIGS. 1 and 2, the FRP used to make header pipes 10 in the gas-liquid contact apparatus of the present invention may be composed of a reinforcing fiber such as glass fiber, carbon fiber or an organic resin fiber (e.g., polyester fiber), and a resin component comprising a 1polyester resin such as unsaturated polyester resin, epoxyacrylate resin (=vinylester resin) or epoxy resin. Among others, FRP composed of glass fiber and a polyester or vinyl ester resin is preferred.
As the material of spray nozzles 11 attached to header pipes 10, there can be used a highly wear-resistant material selected from metallic materials, ceramics, rubber and the like.
The ceramic particles used to form a corrosion-resistant and wear-resistant layer on the outer surface, or on the outer and inner surfaces, of header pipes 10 made of the aforesaid FRP according to the present invention need to have a hardness higher than that of gypsum particles contained in the absorbent slurry. For example, alumina, silicon carbide, tungsten carbide and zirconia can preferably be used.
The content of the ceramic particles used to form the corrosion-resistant and wear-resistant layer may be suitably determined according to the properties and flow velocity of the absorbent slurry, the height to which it is spouted, and the like. The preferred range thereof somewhat varies between the outer surface and the inner surface of the header pipes, because of the difference in environmental conditions. The content in the outer surface is suitably in the range of 5 to 90% by weight and preferably 10 to 70% by weight. If it is less than 5% by weight, the amount of wear caused by the spouted and falling absorbent slurry becomes unduly large under such conditions that the liquid column height is not less than 1 m. If it is greater than 90% by weight, the application of the corrosion-resistant and wear-resistant layer becomes difficult, resulting in an increased processing cost. On the other hand, the content in the inner surface is suitably in the range of 1 to 70% by weight and preferably 5 to 70% by weight. If it is less than 1% by weight, the amount of wear becomes unduly large under such conditions that the flow velocity is not less than 2 m/sec and/or the gypsum concentration is not less than 15% by weight. On the other hand, since the inner surface usually undergoes less wear than the outer surface, sufficient wear resistance is obtained at a content of about 70% by weight.
As the resin used to form the corrosion-resistant and wear-resistant layer, there may be used any of the above-described resins which can be used for the resin component of FRP constituting header pipes 10. The corrosion-resistant and wear-resistant layer may or may not contain a reinforcing fiber. From the viewpoint of ease of fabrication, it is usually preferable that the corrosion-resistant and wear-resistant layer is formed of the same resin as the resin component of FRP constituting header pipes 10 and no reinforcing fiber is incorporated therein.
Header pipes 10 having ceramic particle-containing corrosion-resistant and wear-resistant layers 12 formed on the outer surface thereof according to the present invention can be made, for example, in the following manner. First of all, a mat, cloth or roving consisting of a reinforcing fiber such as glass fiber, carbon fiber or an organic resin fiber is impregnated with a resin such as an epoxy, polyester or vinyl ester resin, and then applied to or wound on the outer surface of a wooden mold having a diameter corresponding to the inside diameter of the header pipes according to a technique such as hand lay-up or winding. Thus, an FRP pipe 10 having a desired wall thickness is made.
Subsequently, 5 to 90% by weight of a ceramic material having a particle diameter of not greater than 1 mm, such as alumina, silicon carbide, tungsten carbide, zirconia or a mixture thereof, is mixed with any of the above-described resins, and the resulting mixture is applied to the outer surface of the FRP pipe with a trowel, brush, spray gun or the like. Thus, a corrosion-resistant and wear-resistant layer 12 consisting of a resin containing ceramic particles and having a thickness of 0.01 to 20 mm is formed on the outer surface of the FRP pipe.
The surfaces of the ceramic particles do not have to be treated by a silane compound or the like, which is commonly used to increase the interface adhesion between ceramic particles and resin. Either surface-treated or non-treated ceramic particles may be used.
Desirable mean particle diameter of the ceramic particles are variable depending on the condition for use. Since the ceramic particles are added in order to enhance wear-resistace of the corrosion-resistant layer, the desirable mean particle diameter thereof reflects on the targetted life time of the corrosion-resistant and wear-resistant layer, depending on a condition under which the gas-liquid contact apparatus is used. When the corrosion-resistant and wear-resistant layer is used for a high gypsum slurry concentration in the gas-liquid contact apparatus, the content of the ceramic particles should be increased in order to lengthen the life time thereof. When the content of the ceramic particles are as high as 90 wt % as shown in the example below, the ceramic particles having a mean particle diameter as large as 1 mm are not suitable. It is because the interspaces among the particles are too large to be filled with the remaining 10 wt % resin so that the resulting pores in the corrosion-resistant and wear-resistant layer remarkably lower the corrosion-resistance and wear-resistance thereof. Accordinly, when the high content of the ceramic particles are required, the ceramic particles having such a small mean particle diameter as 10 μm are desirable. On the other hand, when the content of the ceramic particles is low under the condition where the high wear-resistance is not rquired, the ceramic particles having a wide range of mean particle diameter from small to large may be used. It should be noted-that the larger particles tend to have better wear-resistance.
The thickness of the corrosion-resistant and wear-resistant layer may be determined by the required life time and wear-resistance thereof. From the view of fabrication and economy, the thickness of the corrosion-resistant and wear-resistant layer is practically in the range of 0.01 to 20 mm, preferably in the range of 1 to 5 mm. Accordingly, the mean particle diameter and the amount of the ceramic particles are also determined to obtain the desirable thickness.
Moreover, header pipes 10 having ceramic particle-containing corrosion-resistant and wear-resistant layers 12 and 13 formed on the outer and inner surfaces thereof according to the present invention can be made, for example, in the following manner. First of all, a ceramic material having a particle diameter of not greater than 1 mm, such as alumina, silicon carbide, tungsten carbide, zirconia or a mixture thereof, is mixed with a resin such as an epoxy, polyester or vinyl ester resin in the range of the ceramic material content of 1 to 70% by weight. Using a trowel, brush, spray gun or the like, the resulting mixture is applied to the outer surface of a wooden mold having a diameter corresponding to the inside diameter of the header pipes so as to give a thickness of 0.01 to 20 mm. Thus, an inner corrosion-resistant and wear-resistant layer 13 is formed.
Subsequently, a mat, cloth or roving consisting of a reinforcing fiber such as glass fiber, carbon fiber or an organic resin fiber is impregnated with a resin such as an epoxy, polyester or vinyl ester resin, and then applied to or wound on the aforesaid inner corrosion-resistant and wear-resistant layer 13 according to a technique such as hand lay-up or winding. Thus, an FRP pipe 10 having a desired all thickness is made. Finally, a corrosion-resistant and wear-resistant layer 12 consisting of a resin containing ceramic particles and having a thickness of 0.01 to 20 mm is formed on the outer surface of the FRP pipe in the same manner as described above.
Now, the present invention is more specifically explained in connection with an embodiment in which the gas-liquid contact apparatus of the present invention is applied to the flue gas desulfurizer illustrated in FIG. 3.
As shown in FIG. 3, header pipes 10 are pipes having attached to the upper side thereof a plurality of spray nozzles 11 for spouting an absorbent slurry in the main body 3 of a tower. In the gas-liquid contact apparatus of the present invention, header pipes 10 are made of FRP and the outer surface thereof is formed of a corrosion-resistant and wear-resistant layer 12 of a resin containing 5 to 90% by weight of ceramic particles as shown in FIG. 1. Alternatively, as shown in FIG. 2, the ouster surface thereof is formed of a corrosion-resistant and wear-resistant layer 12 of a resin containing 5 to 90% by weight of ceramic particles, and the inner surface thereof is formed of a corrosion-resistant and wear-resistant layer 13 of a resin containing 1 to 70% by weight of ceramic-particles. When a plurality of header pipes are used, they are not always disposed on the same plane.
In the above desulfurizer, untreated flue gas is introduced, for example, through a duct 8, and brought into contact with an absorbent slurry S fed by means of a circulating pump 4 and spouted upward from spray nozzles 11, so that sulfur dioxide present in the untreated flue gas is removed by absorption into absorbent slurry S. Thereafter, the resulting flue gas is discharged through a duct 9 as the treated flue gas.
During this process, corrosion-resistant and wear-resistant layer 12 formed on the outer surface of header pipes 10 prevents the FRP from being worn by the falling and impingement of the upwardly spouted absorbent slurry S. Moreover, corrosion-resistant and wear-resistant layer 13 formed on the inner surface of header pipes 10 prevents the FRP from being worn by the flow of absorbent slurry S under such conditions that the circulation rate of absorbent slurry S is increased so as to give a flow velocity of greater than 2 m/sec within header pipes 10 and/or the gypsum concentration in absorbent slurry S is greater than 15% by weight.
The gas-liquid contact apparatus of the present invention makes it possible to achieve high corrosion resistance and wear resistance, using inexpensive and lightweight FRP with high impact resistance as a main body of a header pipe. Thus, using a small-volume and simple absorption tower, the purification of flue gas can be performed with as high a degree of desulfurization as has been achievable in the prior art.
That is, the present invention enables header pipes made of FRP to satisfactorily withstand even a highly corrosive and wearing environment in which an absorbent slurry is spouted to a height of 1 m or greater, the flow velocity of a gypsum-containing absorbent slurry is greater than 2 m/sec, and/or the gypsum concentration therein is greater than 15% by weight, resulting in an improvement in the economical efficiency and reliability of the gas-liquid contact apparatus and hence the desulfurizer.
In order to demonstrate the effects of the present invention, the following example is given. The cereramic particles used in the example were not surface-treated.
EXAMPLE 1
Header pipes having the structure illustrated in FIG. 2 were made, and their wear properties were tested in testing apparatus having the construction illustrated in FIG. 3. The header pipes used in these tests were made as follows.
Using a bisphenol-based vinyl resin and ceramic particles as shown in Table 1, a ceramic particle-containing inner corrosion-resistant and wear-resistant layer 13 having a thickness of 3 mm was formed on the outer surface of a wooden mold having an outside diameter of 100 mm. Then, glass fiber impregnated with an isophthalic acid-based polyester resin was superposed thereon by hand lay-up to form an FRP layer 10 having a thickness of 10 mm. In addition, using the same bisphenol-based vinyl resin as used for the aforesaid inner corrosion-resistant and wear-resistant layer and ceramic particles as shown in Table 1, a ceramic particle-containing outer corrosion-resistant and wear-resistant layer 12 having a thickness of 3 mm was formed thereon. The header pipe so made had an overall length of 5 m, and nine spray nozzles were attached thereto at intervals of 0.5 m.
For testing purposes, header pipes made in the above-described manner and conventional header pipes made of the same FRP but containing no ceramic particles in the inner and outer surfaces thereof were installed in testing apparatus having the construction illustrated in FIG. 3. Then, the testing apparatus were operated for 6 months under such conditions that the gypsum concentration in absorbent slurry S ranged from 10 to 30% by weight, the height of the spouted absorbent slurry S ranged from 1 to 5 m, and the flow velocity of absorbent slurry S in the header pipes ranged from 1 to 3 m/sec. Thereafter, the amounts of wear of these header pipes were examined, and the results thus obtained with respect to the outer and inner surfaces are shown in Tables 1 and 2, respectively.
TABLE 1__________________________________________________________________________Ceramic particle Content of ceramic Height of Water of outer Mean particles in outer Gypsum spouted surface after particle corrosion-resistant and concentration in absorbent 6 months'Test diameter wear-resistant absorbent slurry testingNo. Type (μm) layer (wt. %) slurry (wt. %) (m) (mm)__________________________________________________________________________1 -- -- 0 10 1 0.152 -- -- 0 15 1 0.53 -- -- 0 30 1 0.84 -- -- 0 30 5 5.45 Alumina 100 1 15 1 0.2 (Al.sub.2 O.sub.3)6 Al.sub.2 O.sub.3 50 5 15 3 0.257 Al.sub.2 O.sub.3 50 20 20 5 0.28 Al.sub.2 O.sub.3 10 50 30 5 0.159 Al.sub.2 O.sub.3 10 70 30 5 <0.110 Al.sub.2 O.sub.3 10 90 30 5 <0.111 Al.sub.2 O.sub.3 10 50 30 112 Al.sub.2 O.sub.3 10 50 20 5 0.1513 Al.sub.2 O.sub.3 10 50 30 5 0.1514 Silicon 100 5 15 1 0.1 carbide (SiC)15 SiC 10 90 30 5 <0.116 Tungsten 100 5 15 1 0.1 carbide (WC)17 WC 10 90 30 5 <0.118 Alumina 100 5 15 3 0.25 (Al.sub.2 O.sub.3)19 Al.sub.2 O.sub.3 50 20 20 5 0.2__________________________________________________________________________
TABLE 2__________________________________________________________________________Ceramic particle Content of ceramic Flow velocity Wear of inner Mean particles in inner Gypsum of absorbent surface after particle corrosion-resistant and concentration in slurry in 6 months'Test diameter wear-resistant absorbent header pipe testingNo. Type (μm) layer (wt. %) slurry (wt. %) (m/sec) (mm)__________________________________________________________________________1 -- -- 0 10 1 0.12 -- -- 0 15 2 0.43 -- -- 0 30 2 0.74 -- -- 0 30 3 2.35 Alumina 10 50 15 2 <0.1 (Al.sub.2 O.sub.3)6 Al.sub.2 O.sub.3 10 50 15 2 <0.17 Al.sub.2 O.sub.3 10 50 20 2 <0.18 Al.sub.2 O.sub.3 10 50 30 3 0.19 Al.sub.2 O.sub.3 10 50 30 2 <0.110 Al.sub.2 O.sub.3 10 50 30 2 <0.111 Al.sub.2 O.sub.3 100 1 30 3 0.3512 Al.sub.2 O.sub.3 50 20 20 2 0.213 Al.sub.2 O.sub.3 10 70 30 3 <0.114 Silicon 100 1 15 2 <0.1 carbide (SiC)15 SiC 10 70 30 3 <0.116 Tungsten 100 1 15 2 <0.1 carbide (WC)17 WC 10 70 30 3 <0.118 Alumina 100 5 15 2 0.1 (Al.sub.2 O.sub.3)19 Al.sub.2 O.sub.3 50 10 20 2 <0.1__________________________________________________________________________
As shown in Table 1, under such conditions that the gypsum concentration in absorbent slurry S was not less than 15% by weight and the height of the spouted absorbent slurry S was not less than 1 m, only slight wear was caused in the header pipes containing not less than 5% by weight of ceramic particles (comprising alumina, silicon carbide or tungsten carbide) in the-outer surface thereof, whereas heavy wear damage was observed in the other header pipes.
Moreover, as shown in Table 2, when absorbent slurry S having a gypsum concentration of 15% by weight was made to flow through the header pipes at a flow velocity of not less than 2 m/sec, only slight wear was caused in the header pipes containing not less than 1% by weight of ceramic particles (comprising alumina, silicon carbide or tungsten carbide) in the inner surface thereof, whereas heavy wear damage was observed in the other header pipes. | 4y
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. Provisional Patent Application Ser. No. 61/870,986, filed on Aug. 28, 2013, the contents of which are herein incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to arrows suitable for use with bowfishing and in particular to an arrow tip suitable for use in bowfishing.
[0003] Bowfishing is an archery technique using specialized bows and arrows for fishing. A bowfishing bow may have a lower draw weight than a standard bows as well as a constant draw to allow rapid and frequent shooting without tiring the archer. The bowfishing bow may have bowfishing line stored in a canister or reel attached to the bow. One end of the bowfishing line is attached to the arrow so that when the arrow is released, the line pays out allowing the arrow and fish to be retrieved by reeling the line in. A bowfishing reel suitable for use in this purpose is described in U.S. Pat. Nos. 4,383,516 and 6,634,350 by the inventor of the present invention and hereby incorporated, by reference. The line may be attached to the arrow using a slide that moves freely up and down the arrow shaft. Before the arrow is released, the slide may be positioned in front of the arrow rest and bowstring and may remain in front of the arrow rest as the arrow is released to reduce risk of entangling either the bow or the bowstring. Slides suitable for this purpose are described in U.S. Pat. No. 6,517,453 also by the inventor of the present invention and hereby incorporated by reference.
[0004] The arrows used for bowfishing are normally fashioned out of high-strength fiberglass or carbon fiber composites to better survive impact with a stony bottom of a lake or stream. For similar reasons, the arrow tips used for bowfishing are designed with the expectation that they may strike hard surfaces. A common arrow tip for bowfishing, provides a compact cylindrical body of hardened steel or the like having a pyramidal tip formed of 3-6 flat or hollow ground faces tapering to a point. The faces abut each other at sharp edges to provide a cutting action as the arrow tip passes into the fish.
[0005] The arrow tip may attach to the fiberglass arrow shaft by means of a threaded adapter, the latter providing an interface between the arrow tip and the arrow shaft. Generally the threaded adapter receives the arrow shaft in a blind bore in the rear of the threaded adapter.
[0006] The arrow shaft is held within the bore, for example, with epoxy or the like. An opposite end of the threaded adapter provides a threaded stud or socket that may engage a corresponding socket or stud on the arrow tip. This threaded connection allows damaged arrow tips to be readily replaced by unthreading the arrow tip from the threaded adapter and threading a new arrow tip in its place.
[0007] The threaded adapter may provide sidewardly extending barbs that help retain the fish when the arrow is retrieved. In some cases, the barbs are held extended by the presence of the arrow tip as attached to the threaded adapter. In these cases, the arrow tip may be unscrewed to allow the barbs to be retracted or reversed to assist in removing the fish from the arrow.
[0008] It will be understood that it is important that the arrow tip be readily removable for replacement when it is damaged and in some cases for a resetting of the barbs for extraction of the arrow from the fish. Yet the vibration of impact after repeated shots can cause the arrow tip to become unthreaded and lost.
SUMMARY OF THE INVENTION
[0009] The present invention provides an arrow tip suitable for bowfishing having spiral cut faces and edges. In one embodiment, the spiral coordinates with the threaded engagement between the arrow tip and the adapter so that impact of the arrow tip against stones or the like and passage of the arrow tip through the water tend to tighten the arrow tip to prevent its loss.
[0010] Specifically one embodiment of the invention provides an arrow tip having a tip body with an outer wall extending about a central axis. A point is formed at a front end providing a tapering inward of the outer walls towards the central axis to an apex on the central axis, wherein the point is formed from a plurality of faces joined at circumferentially abutting edges, the faces and edges extending about the axis in a helical path. A threaded attachment at a rear end of the tip extends along the axis to receive a second threaded attachment on an arrow shaft to releasably attach the arrow tip to the arrow shaft by rotationally threading the threaded attachment on the second threaded attachment.
[0011] It is thus a feature of one embodiment of the invention to provide a substantially new form of sharpened point on an arrow.
[0012] The apex may be a point of convergence of the helical faces and edges.
[0013] It is thus a feature of at least one embodiment of the invention to provide an arrow tip that converges to a point for superior penetration.
[0014] The helical faces and helical edges may run counterclockwise with respect to the central axis of the tip body viewed from the front end.
[0015] It is thus a feature of at least one embodiment of the invention to provide a helical form that conforms to standard right-handed threads.
[0016] The faces may be hollow wound.
[0017] It is thus a feature of at least one embodiment of the invention to permit multiple faces while preserving relatively sharp edges that resist dulling.
[0018] The helical faces and helical edges may have a rotational sense relative to the threaded attachment tending to tighten the threaded attachment when the tip passes through a resisting material with the apex in a leading position.
[0019] It is another feature of at least one embodiment of this invention to provide an arrow tip with helical faces that tend to tighten the arrow tip onto the arrow shaft when the arrow tip strikes a surface.
[0020] The tip may be part of an arrow providing a linear shaft, a nock, an adapter, and at least one arrow barbs that are retained against some range of movement by the tip.
[0021] It is thus one feature of at least one embodiment of the invention to provide a tip that may be retained on the arrow with only finger tightening so that it may be loosened for release of the barbs and yet which will resist dislodgment when the arrow strikes water, fish, or a hard surface.
[0022] These particular features and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an exploded, side elevational view of one embodiment of the arrow tip of the present invention as may be received on a barbed adapter attached to an arrow shaft:
[0024] FIGS. 2 a and 2 b are front and rear views of the arrow tip of FIG. 1 showing the spiral edges and spiral faces of the arrow tip and the threaded socket of the arrow tip;
[0025] FIG. 3 is a side elevational view of a machining apparatus for cutting spiral edges on the arrow tip;
[0026] FIG. 4 is a top plan view of the machining apparatus of FIG. 3 ;
[0027] FIGS. 5-8 are left elevational, front elevational, rear elevational, and right elevational views of the arrow tip FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0028] Referring now to FIG. 1 , an arrow 10 for use with the present invention may provide for a carbon fiber or fiberglass arrow shaft 12 having a cylindrical cross-section, for example, 5/16 inch in diameter and approximately thirty-two inches long. A rear end of the arrow shaft 12 provides an arrow nock (not shown).
[0029] A front end of the arrow shaft 12 may attach to an adapter 14 by being received within a blind bore socket 16 of equal diameter in the adapter 14 . The arrow shaft 12 may be held, within the socket 16 with epoxy 18 or the like.
[0030] The adapter 14 may provide a generally cylindrical metal body supporting the bore socket 16 at a rear end and extending along an axis 20 common to the arrow shaft 12 to terminate at a threaded boss 22 at a front end. An arrow tip 24 also extending generally along axis 20 and having a rearwardly-threaded bore 26 (also shown in FIG. 2 b ) may receive the threaded boss 22 to attach the arrow tip 24 to the adapter 14 .
[0031] Pivoting barbs 28 may be attached to the adapter 14 to extend outwardly from the adapter 14 and back toward the arrow shaft 12 . These barbs 28 help retain a fish on the arrow 10 after the arrow tip 24 and the adapter 14 and barbs 28 have passed through a fish. In order to remove the fish from the barbs 28 , the barbs 28 may fold flat against the adapter 14 (when the arrow tip 24 has been loosened or removed from the threaded boss 22 ). When the arrow tip 24 is attached to the threaded boss 22 , the barbs 28 may rest against the adapter 14 or may extend such that they are perpendicular to the adapter 14 . However, the barbs 28 are prevented from extending further than perpendicular to the adapter 14 as long as the arrow tip 24 is attached to the threaded boss 22 . An arrow and barb system suitable for the present invention is described in U.S. patent application Ser. No. 14/457,677 hereby incorporated by reference.
[0032] One or both of the threaded boss 22 and threaded bore 26 may be coated with a locking polymer 31 (or may incorporate a polymer insert) serving to lock, the threads together by deformation of the polymer 31 coupled with engaging of the threads of the threaded boss 22 and threaded bore 26 together. The locking polymer 31 allows the arrow tip 24 to better resist vibration induced when the arrow is shot, preventing unthreading from the threaded boss 22 .
[0033] Referring now to FIGS. 1 and 2 a , the arrow tip 24 provides for a cylindrical body 30 holding the threaded bore 26 and substantially equal in diameter to the adapter 14 as it attaches to the adapter 14 . The cylindrical body 30 extends along the axis 20 to a forward tip 33 of the arrow tip 24 , the latter of which is sharpened to a point 32 . In particular, forward tip 33 is formed by a set of converging flat or hollow ground spiral faces 34 converging at the point 32 . The spiral faces 34 abut along spiral edges 36 . The spiral faces 34 and spiral edges 36 define a helical path running clockwise to the axis 20 from threaded bore 26 to point 32 . In one embodiment five spiral faces 34 are provided (as depicted); however, the invention contemplates that between three and six spiral faces 34 and preferably at least five spiral faces 34 will normally be employed.
[0034] In one embodiment, the spiral faces 34 and spiral edges 36 curve in a counterclockwise direction as viewed from the point 32 . In this case the thread of the threaded boss 22 may be a standard right-hand thread allowing the arrow tip 24 to tighten on the boss 22 with clockwise rotation of the arrow tip 24 as viewed from the point 32 . It will be appreciated that as the arrow 10 flies, impacts with a stationary surface or passage through a medium such as water will cause the spiral faces 34 or spiral edges 36 to impart a clockwise torsion on the arrow tip 24 tending to tighten the arrow tip 24 onto the adapter 14 .
[0035] Referring now to FIG. 3 , the arrow tip 24 may be fabricated from a stainless, titanium, or hardened steel cylinder 38 providing the cylindrical body 30 of the arrow tip 24 . The cylinder may have a diameter of ¼″ to ⅝″, A cutter 40 is rotated about an axis 42 parallel to an axis 20 (along which the cylindrical body 30 extends) to cut the faces 34 . The cutter 40 may be a carbide tool or the like, as shown, or the surface of a grinding wheel or other similar cutting mechanism. The radius of rotation of the cutter 40 in an arc about axis 42 defines a hollow cut of the faces 34 . This hollow face sharpens the edges 36 beyond that which could be obtained by a simple faceting and provides edges that better resist dulling in the manner of a hollow ground knife-edge.
[0036] A pyramidal tapering of the faces 34 to the point 32 may be provided by an angled translation of the center of rotation of the cutter 40 along a taper path 46 following an angle of a taper of the arrow tip 24 while preserving a parallel alignment between the axis 42 and axis 20 . A spiraling of the faces 34 is provided by slight rotation 48 of the cylindrical body 30 about axis 20 as the arc of the cutter 40 is translated along path 46 . The amount of rotation 48 during the full translation along path 46 is preferably between two and 30 degrees. In order to provide the desired spiraling described above, the rotation 48 may be counterclockwise as the cutter 40 moves upward along path 46 as depicted in FIG. 3 .
[0037] It will be appreciated that the spiral faces 34 are at all times circumscribed by the cylinder defined by the cylindrical body 30 and that the arrow tip 24 may be of unitary construction machined from a single cylinder of metal.
[0038] Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, and “below” refer to directions in the drawings to which reference is made. Terms such as “front”, “back”, “rear”, “bottom” and “side”, describe the orientation of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first”, “second” and other such numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context.
[0039] When introducing elements or features of the present disclosure and the exemplary embodiments, the articles “a”, “an”. “the” and “said” are intended to mean that there are one or more of such elements or features. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements or features other than those specifically noted. It is further to be understood that the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
[0040] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein and the claims should be understood to include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. All of the publications described herein, including patents and non-patent publications are hereby incorporated herein by reference in their entireties. | 4y
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BACKGROUND OF THE INVENTION
This invention relates to ion implantation and, more particularly, to methods and apparatus for improving ion implanatation dose accuracy by reducing measurement errors due to pressure variations in the implant chamber.
Ion implantation has become a standard technique for introducing impurity dopants into semiconductor wafers. A beam of ions is generated in a source and is directed with varying degrees of acceleration toward a target wafer. The ions implanted into the semiconductor material form the various elements of an integrated circuit. Ion Implantation systems typically include an ion source, ion optics for removing undesired ion species and for focusing the beam, means for deflecting the beam over the target area, and an end station for mounting and exchanging wafers. The entire region between the ion source and the semiconductor wafer is maintained at high vacuum to prevent dispersion of the ion beam by collisions with gas molecules.
In commercial ion implantation systems, wafers are introduced into a vacuum ion implantation chamber through an isolation lock, are implanted and then are removed through the isolation lock. In some systems, the wafers remain in the isolation lock and are implanted through an open gate valve. Prior to implantation, the vacuum chamber is maintained at a prescribed baseline pressure level by a vacuum pumping system. When a wafer is introduced into the chamber through the isolation lock, a substantial increase in pressure occurs due to gas introduced with the wafer and outgassing of the wafer and lock surfaces. When the ion beam is applied to the wafer, another pressure increase occurs, due in part to the presence of the ion beam in the chamber, and in part to particles dislodged from the wafer by impact of the ion beam. The gas responsible for the pressure increase, or pressure burst, is removed by the vacuum pumping system, so as to reduce the pressure at a rate determined by several factors described hereinafter. In order to achieve high throughput with the ion implantation system, it is impractical to wait until the pressure has returned to its baseline level. Typically, ion implantation can be performed at a pressure which is an order of magnitude above the baseline pressure. Thus, implantation is begun shortly after the wafers are introduced into the chamber, and, as implantation proceeds, the chamber pressure is gradually reduced.
In the fabrication of microminiature integrated circuits, it is important to implant precisely measured quantities of impurity dopants to achieve predictable device performance. Ion implanters customarily utilize a Faraday charge collection system to measure the ion dosage. In such a system, the wafer is positioned in a Faraday cage which detects the charged particles in the ion beam. The measurement is integrated over time to obtain a measurement of total ion dosage applied to the wafer.
However, the Faraday system accuracy is sensitive to pressure. The residual gas in the vacuum chamber produces errors in the measured dose due to collisions between ions in the beam and residual gas molecules outside the Faraday system. When these collisions occur, some of the ions in the beam are neutralized. Since the Faraday system registers dopant atoms only if they carry an electrical charge, the Faraday system is not able to measure the neutralized portion of the ion beam, and a dose error is introduced. The magnitude of the error depends on the number of neutralizing collisions and, hence, upon the chamber pressure.
Since ion implantation is usually performed during vacuum pumping of gas introduced with the target wafers, the pressure is variable and determination of resulting dose errors is difficult. Several factors cause the pressure level as a function of time during the implant to be unpredictable. Some of these factors are as follows:
(1) The pressure varies with ion beam current.
(2) The pressure at any instant depends on the rate of vacuum pumping, which can vary for a number of reasons.
(3) Undesired leakage into the vacuum chamber causes variations in the pressure versus time curve.
(4) Variations in wafer outgassing, such as water vapor, and particularly outgassing by photoresist mask layers applied to the wafers.
(5) The time of the implant affects the final pressure reached.
(6) Chamber contamination can cause variations in pressure.
The pressure during implantation will vary depending on the above factors, thereby causing an error between the actual dose and the measured dose. In the past, Faraday system designs have been proposed which exhibit reduced sensitivity to chamber pressure. However, it is desired to improve dose accuracy regardless of Faraday system configuration.
It is a general object of the present invention to provide novel ion implantation apparatus and methods.
It is another object of the present invention to provide methods and apparatus for improving the accuracy of ion implanted impurity dosage.
It is still another object of the present invention to provide methods and apparatus for reducing pressure variations during ion implantation.
SUMMARY OF THE INVENTION
According to the present invention, these and other objects and advantages are achieved in ion implantation apparatus comprising a processing chamber, means for evacuating the chamber to a baseline pressure, means for introducing a workpiece into the chamber, thereby causing an undesired increase in chamber pressure, means for directing a beam of positively charged ions at the workpiece, and means for controlling the pressure in the chamber after introduction of the workpiece within a specified intermediate pressure range higher than the baseline pressure, thereby reducing pressure variations during implantation.
According to another aspect of the invention, there is provided a method for ion implantation comprising the steps of evacuating a processing chamber to a baseline pressure, introducing a workpiece into the chamber thereby causing an increase in pressure, directing a beam of positively charged ions at the workpiece, and controlling the pressure in the chamber after introduction of the workpiece within a predetermined intermediate pressure range higher than the baseline pressure thereby reducing pressure variations during implantation.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, together with other and further objects, advantages, and capabilities thereof, reference may be had to the accompanying drawings which are incorporated herein by reference, and in which:
FIG. 1 is a simplified schematic diagram of the apparatus in accordance with the present invention;
FIG. 2 is a graphic representation of pressure as a function of time in prior art ion implanters; and
FIG. 3 is a graphic representation of pressure as a function of time of the apparatus shown in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
An end station for a serial ion implantation system in accordance with the present invention is shown in simplified form in FIG. 1. An ion beam 10 is generated in an ion source, is accelerated to the desired energy, typically 10 to 200 KeV, is momentum analyzed to remove undesired ion species, and is focused in the plane of the target wafer. The ion source and ion optical elements are shown schematically at 8. In a serial system which implants one wafer at a time, the ion beam is electrostatically scanned over the area of the wafer to provide uniform dosage per unit area. Other systems utilize mechanical scanning of the wafer or a combination of mechanical scanning and beam deflection to distribute the ion dosage. The scanning technique is not relevant to the present invention. Systems for generating the ion beam 10 are well known in the art and are commercially utilized in ion implantation equipment. The entire region traversed by the ion beam, between the source and the wafer, is enclosed by a vacuum chamber 12, which is evacuated by a vacuum pumping system. The end station is evacuated by a vacuum pump 14. Semiconductor wafers are introduced into the vacuum chamber 12 through an isolation lock 16, are processed by the ion beam 10 and are removed from the chamber through the isolation lock 16. A semiconductor wafer 20 is lifted from a cassette wafer holder (not shown) by a wafer handler 22 and is clamped on a chamber door 24. The chamber door 24 is sealed to the isolation lock 16 by a door control 26. The lock 16 is then evacuated by a roughing vacuum pump 30; and a gate valve 32 between the lock 16 and the vacuum chamber 12 is opened. The operation of the wafer handling system is shown and described in more detail in U.S. Pat. No. 4,449,885. The system is typically provided with a beam gate (not shown) for preventing the beam from reaching the target wafer except during the implant cycle.
A Faraday charge collection system 36 is mounted to receive the ion beam 10 through an aperture 40. The wafer 20 is positioned at the downstream end of the Faraday system 36 and forms part of the charge collection surface. The Faraday system 36 is electrically isolated from the vacuum chamber 12 and is connected to a dose measurement system 42. The Faraday system 36 operates by sensing the charges in the ion beam and converting the charges to a current. The current is sensed and integrated over time by the dose measurement system 42 to provide a measurement of the cumulative impurity dosage implanted in the wafer 20. Typically, when a prescribed dosage is reached, ion implantation of the wafer is automatically terminated. The use of erroneous measured dose information to determine the implant end point results in actual dose errors in the target wafers. In the fabrication of microminiature integrated circuit devices, high dose accuracy is necessary to achieve predictable device performance. Therefore, the reduction of dose measurement errors is an important objective.
One of the variables affecting the accuracy of the measured dose is the pressure in the implant chamber. Collisions between ions in the beam and residual gas molecules can produce neutral atoms which are not registered by the Faraday system, although such neutral atoms are implanted into the target wafer and affect wafer properties. Neutralizing collisions, therefore, cause errors in the measured dose, the magnitude of which increases as the pressure of the residual gas increases. For given pressure level and ion beam current, a correction factor can be added to the measured dose. However, in the typical production ion implanter, the pressure varies during implantation, thereby making it impractical to compensate for errors in real time by the use of correction factors.
The pressure variation during ion implantation in accordance with prior art techniques is illustrated graphically in FIG. 2. The baseline pressure P B is the pressure level obtained in the vacuum chamber 12 after operation of the vacuum pumping system for an extended period of time. At time t 1 , the gate valve 32 is opened to expose a wafer for implantation and the pressure rapidly rises to a level P A due to the introduction of gas from the isolation lock 16. The pressure is reduced by operation of the vacuum pump 14, as shown by the curve 50 in FIG. 2, until an equilibrium pressure is reached. During this time, the wafer is implanted, and dose is monitored by the dose measurement system 42. It is assumed that, during the time t 1 to t 2 , the pressure indicated by curve 50 is within a range which is acceptable for ion implantation. If this is not the case, it is necessary to delay the start of the implant until the pressure is reduced to an acceptable level. At time t 2 , implantation is completed and the gate valve 32 is closed for exchange of wafers. At time t 3 , the gate valve is reopened and a new wafer is exposed for ion implantation. It can be seen that the pressure during ion implantation is variable, thereby causing a time-varying dose error.
Furthermore, the pressure in the chamber does not always follow the curve 50 during ion implantation. The pressure-time curve depends both on the quantity of gas in the chamber and the rate of vacuum pumping. The rate of pumping is more or less fixed, except for long term aging effects. However, the quantity of gas depends on beam current, chamber leakage, wafer outgassing, chamber outgassing and gas introduced from the isolation lock, all of which are variable to some extent. This variability is illustrated in FIG. 2 by the curve 52 which represents the pressure during implantation of a second wafer. The initial pressure after opening of the gate valve is higher than for the previous wafer since more gas was introduced. In addition, a pressure burst 54 occurs when the beam is applied to the wafer, due to the presence of a photoresist masking layer on the wafer. The photoresist outgassing effect is well known to those skilled in the art. The curve 52 is, therefore, shifted upwards in relation to the curve 50, resulting in a different dose measurement error.
In accordance with the present invention, the pressure in the chamber during ion implantation of a wafer is prevented from going below a predetermined intermediate pressure level P C which is higher than the baseline pressure P B . With reference to FIG. 3, the pressure P C is intermediate the baseline pressure P B , and the pressure P A , which occurs after opening of the gate valve 32. After opening the gate valve 32, the chamber pressure is reduced by the vacuum pump 14 until the pressure P C is reached. Preferably, the implant is not started until the chamber pressure reaches the level P C . Alternatively, if somewhat greater dose error is acceptable, the implant can be started before the chamber pressure reaches the level P C . The pressure is then controlled within prescribed limits at the level P C until completion of the implant. Therefore, the variations in pressure described hereinabove are, to a large extent, eliminated.
Apparatus for maintaining the pressure at the level P C is shown in FIG. 1. A controllable vacuum valve 60 is connected in the conduit between the vacuum chamber 12 and the vacuum pump 14. The vacuum valve 60 includes means for controlling the flow of gas between the chamber 12 and the vacuum pump 14. In the present example, the valve 60 includes vanes 62 which can be turned to block flow of gas into the vacuum pump 14 or turned to permit free flow of gas. The position of the vanes 62 is controlled by a valve motor 64. An example of a vacuum valve 60 is a type 253 Exhaust Valve available from MKS Instruments, Inc. A pressure sensor 66, such as an ion gauge is connected to measure the pressure in the chamber 12. A signal representing the measured pressure is supplied to a valve controller 70, the output of which is coupled to the valve motor 64. The valve controller 70 also receives an enable input from the dose measurement system 42, which enables its operation after a wafer is introduced into the chamber. The controller 70 is inhibited after completion of the implant. A pressure set level input establishes the level P C at which the pressure is controlled. The intermediate pressure level P C can be controlled at a fixed level with a linear control system or can be controlled to remain within prescribed upper and lower limits in accordance with known control techniques.
In operation, the valve controller 70 receives a signal representative of the pressure in the chamber 12 from the pressure sensor 66. The pressure signal is compared with a reference level representative of the desired pressure P C . When the pressure in the chamber is above the reference level, the valve controller 70 provides a signal to the valve motor 64 to open the valve 60, thereby allowing maximum vacuum pumping of the chamber 12. When the pressure reaches the level P C , the valve controller 70 provides a signal to the valve motor 64 to partially close the vanes 62, thereby restricting flow of gas into the vacuum pump 14. The valve 60 is not completely closed since some vacuum pumping is required to remove gas leaking into the chamber and outgassing products. The pressure control apparatus maintains the pressure in the chamber at the level P C for the remainder of the ion implantation cycle. The pressure control apparatus can be inhibited when wafers are not being implanted, thereby permitting the pressure to return to the baseline level P B . In an example of the system described above, the baseline pressure P B is on the order of 5×10 -7 torr, while the intermediate pressure P c is in the range of 2×10 -6 to 4×10 -6 torr. It will be understood, however, that the baseline pressure P B and the intermediate pressure P C can be established at any desired level in accordance with the present invention.
It can be seen from FIG. 3 that the pressure during implantation is maintained more or less constant. Therefore, a dose correction for that pressure level P C can be calculated or determined empirically, and added to the measured dose. The resulting dose measurement and applied dose are thereby improved in accuracy.
While there has been shown and described what is at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims. | 4y
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FIELD OF INVENTION
The invention relates to the field of engineering with respect to combustion of gaseous fuel and gas heaters/burners. More specifically, the present invention relates to radiant gas burners applied both in industrial and consumer applications.
Infrared Radiation gas burners, alternatively referred to hereinafter as IR or radiant burners, allow the replacement of heat transfer by convection with more economical radiant or convective radiant means. IR gas burners enable increased heat transfer efficiency to an object being heated by using radiant heat exchange. Due to efficient radiant cooling of an emitting surface, the temperature in the combustion zone decreases which results in a much lower nitric oxide (NO) content in the combustion products.
BACKGROUND OF THE INVENTION
Ceramic matrices or sets of metallic meshes are used as radiating elements in radiant gas heaters. A radiant gas burner with a radiating element in the form of a two-layer ceramic matrix is described in U.S. Pat. No. 4,889,481. A downstream air-gas mixture motion is therein described, wherein a burner body comprises a first layer of porous ceramic material adjacent an inlet side and a second layer of porous ceramic material adjacent an outlet side. The first layer is 0.25 mm thick and possesses a porous structure with pore diameter of between 0.01 and 2.5 mm. The thickness of the second layer is 1.25 cm and also includes a porous structure with a pore diameter of between 1.25 and 10 mm. The shortcomings of the above described burner include high flow resistance and brittleness of the material layers (ceramic matrix).
Industrial IR burners with low carbonic oxide (CO) and nitric oxide (NO) content in combustion products are known, for example, from Russian patent publication no. 2,084,762. The typical industrial IR burner, described therein, consists of a casing, IR deflector, an injector with a nozzle and mixer, a reflector with a shelf, a radiating ceramic mouthpiece, and a mesh. Accommodating the reflector at some distance from the injector's outlet allows uniform combustion along the whole burner's surface and reduces the carbonic oxide and nitric oxide content in the combustion products. One of the shortcomings of this type of burner is that the ceramic mouthpiece poorly withstands thermal and physical shocks and thus, is of little use in burners for domestic gas cookers. Additionally, burners with ceramic mouthpieces have a limited power control range.
An industrial radiant burner is also known (see for example U.S. Pat. No. 4,437,833) to work in heat units using natural and liquefied gas of medium pressure. This type of industrial radiant burner usually consists of a casing, a nozzle unit, an injector, a dissector, an emitting orifice, and a screen mesh. The emitting orifice can be a unit of 32 holed ceramic plates, for example, having a fire channel diameter of 0.85 mm. The casing can include an emitter consisting of refractory mesh and a reflecting screen of metallic wire fixed in the casing. Combustion occurs in between the refractory mesh and the reflecting screen. To provide uniform air-gas mixture flow distribution, dissector plates are accommodated inside the casing. The major drawbacks of the industrial radiating burner, as of all burners with ceramic radiating elements, are insufficient resistance to physical and thermal shocks, small power control range, and high flow resistance.
Using metallic meshes, instead of ceramic radiating elements, has found application in radiating burners for hot-water boilers. These types of burners consist of a flat holder with a supply gas line, see for example U.S. Pat. No. 5,474,443. There is a radiating element fixed on the holder that constitutes a metallic mesh of hemispherical shape and at least a one holed gas-distributing surface of the same shape. Air-gas mixture combustion occurs above the mesh surface. To obtain sufficiently complete combustion above the surface of the metallic mesh, one needs an object returning part of the mesh emission back towards the metallic mesh. Such an object in the burner considered can be a boiler furnace surface surrounding the burner, thereby limiting this type of application in other devices.
Other challenges associated with metallic emitters include a larger portion of radiant energy from the emitter going in the opposite direction of the heat receiver, thereby resulting in undesirable heating of the burner's casing.
Another metallic mesh IR burner is known and comprises a set of metallic meshes located downstream from the flow of the air-gas mixture. A first distributing mesh converts a dynamic component of the pressure into a static one. At the same time, the first mesh shields the burner's casing against backspattered emission. A second and a third mesh are coupled as one pack and form a burner's emitter. A fourth protective mesh guards the emitter against mechanical damages. The burner also accommodates a gas nozzle and an injection air-gas mixer located in parallel with, and under, a distributing mesh (O. N. Bryukhanov et. al., Unified Metallic-Mesh IR Burner, Gazovaya Promyshlennost, N 3, 1985). In the given burner, the first mesh is made of a punched metallic plate. Efficiency of “trapping” backscattered emission via the mesh(es) is directly related to the total area of the holes made in the plate, i.e. with a real plate cross-section. Increasing the efficiency of backscattered emission “trapping” requires lower “real” plate cross-section. Meeting this requirement will lead to high flow resistance of the gas dissector and consequently to lower working capacity of the burner in general. This is a significant drawback of the given design of the gas dissector.
Another disadvantage of the aforementioned burner is that the location of the air-gas mixer does not ensure uniform distribution of the air-gas mixture on the emitter surface and causes additional flow resistance. Further shortcomings of the burner also include the fact that structurally reliable automatic ignition can't be provided. Ignition can be done from outside the burner only, i.e. from above the latter downstream air-gas mixture flow towards the mesh. If one uses spark, resistive or another ignition, during the burner operation, the ignition unit will be within an undesirable high temperature zone.
SUMMARY OF THE DISCLOSURE
A radiant gas burner is provided including a burner having a casing with a first aperture therethrough. The burner further included at least one air-gas mixer connected to the casing to provide an air-gas mixture flow. The casing includes a gas dissector between the air-gas mixer and an emitter whereby the air-gas mixture flows through the dissector. The dissector comprises a grid having ribs defining an upper grid plane and a lower grid plane.
A radiant gas burner is provided including a casing adapted for connection with an air-gas mixing and supply system having a flux dissector and a mixer. The burner further includes a metallic mesh emitter, inside the casing, having lower and upper meshes. The lower mesh and the upper mesh each have porous openings. The lower mesh openings have a size and the upper mesh openings have a size. The lower mesh opening size is less than the upper mesh opening size. Each of the lower and upper meshes has a radius of curvature greater than the burner's diameter.
A radiant gas burner is provided including a casing adapted for connection with an air-gas mixing and supply system. The burner includes a metallic mesh emitter, inside the casing, having a lower mesh and an upper mesh. The lower mesh is spaced apart from the upper mesh. The lower mesh and the upper mesh are shaped substantially in the form of a lens. At least one of the lower and upper meshes forming a convex side of the lens shape.
BRIEF DESCRIPTION OF THE DRAWINGS
Various exemplary embodiments according to this invention will be described in detail, with reference to the following FIGURES wherein:
FIG. 1 is a cross-sectional view of a first embodiment of a radiant gas burner having emitter meshes in the form of a convex-concave lens; and,
FIG. 2 is a cross-sectional view along line 2 - 2 of the gas burner according to FIG. 1 ;
FIG. 3 is a detailed view of area 3 including a gas dissector grid of the gas burner according to FIG. 1 ;
FIG. 4 is a detailed view of an alternative gas dissector grid; and,
FIG. 5 is a cross-sectional view of a second embodiment of a radiant gas burner having emitter meshes in the form of a biconvex lens.
DETAILED DESCRIPTION
The given invention, to be described in more detail below, provides for a radiant gas burner which improves the quality of gas mixture combustion, reduces nitric oxide and carbonic oxide content in the combustion products, and increases the burner's efficiency owing to more uniform air-gas mixture flow. The mixture can be introduced tangentially into the casing and allowed to flow through a gas dissector, the gas dissector increases uniformity of the air-gas mixture flow. Additionally, the gas dissector acts as a shield to catch backscattered emission and as a heat exchanger to heat the air-gas mixture at the same time.
The design of the radiant gas burner described in detail below, assures reliable automatic ignition owing to the location of the apertures available in the burner's casing and the gas dissector.
Location of emitter meshes is also an important improvement of the radiant gas burner. In one embodiment a lower and an upper mesh can be arranged so that a combustion zone is a biconvex lens. Part of the IR radiation from the lower and upper meshes is focused onto an inter-mesh zone of combustion, intensifying the latter. The result is that gas combustion quality increases and carbonic oxide content in the combustion products decreases. In another embodiment, the meshes can be disposed in such a way that the combustion zone forms a convex-concave lens, whereas both meshes are placed with a convex side facing the air-gas mixture flux.
Referring to FIGS. 1-5 , where the components of a radiant gas burner to combust gas fuel are therein provided, including a casing with an aperture to ignite air-gas mixture, an air-gas mixer connected to the casing, and a gas dissector installed in the casing generally transverse to air-gas mixture flux. The gas dissector can be a grid including ribs having an inclination of about 50-60° relative to a plane transverse to a central axis a. The edges of adjacent ribs can be in the same plane perpendicular to that of a grid. The ribs can be in the form of flat or punched plates, or concentric cone rings.
The radiant gas burner also includes a metallic-mesh emitter installed in the casing thereof generally perpendicular to the air-gas mixture flux. The emitter accommodates at least lower and upper meshes downstream from the air-gas mixture motion, and can include different sized mesh openings. The emitter meshes can be installed into the casing thereof so that they form an inner cavity in the form of a lens. The lens form can have a curvature radius of at least the burner's diameter and can have a thickness of at least 8-10 times the size of the lower mesh openings. In addition, the upper and lower meshes of the emitter can form a biconvex or convex-concave lens.
To facilitate automatic ignition of the air-gas mixture, a first aperture in the casing can be provided between the upper and lower meshes of the emitter. A second aperture can be provided in the dissector. The apertures can be of the same size and aligned such that there is a space therebetween.
Improvements are particularly secured by the design of the radiant gas burner that includes a casing in the form of a cylinder and an air-gas mixer connected with the casing thereof so as to ensure air-gas mixture input tangentially. The radiant gas burner can have one or several air-gas mixers of the same or different capacity, connected to the casing thereof as to ensure the air-gas mixture input into the casing in one direction (i.e. clockwise or counter-clockwise).
The casing of the radiant gas burner can consist of two or more parts with a separate air-gas mixture supply to each of them.
Referring now to FIGS. 1 and 2 , FIG. 1 displays a first embodiment of a radiant gas burner for gas fuel combustion, which comprises a cylindrical casing 1 , an injection-type air-gas mixer 2 , a gas dissector 3 a , and a metallic-mesh emitter 4 having a lower mesh 5 and an tipper mesh 6 forming a convex-concave lens. The casing includes an aperture 7 located in between the lower mesh 5 and the upper mesh 6 of emitter 4 . Gas dissector 3 a can also include an aperture 8 adjoining casing 1 (refer to FIG. 2 ). Apertures 7 and 8 can be the same size and can be located so that the distance between their centers is minimal.
The radiant gas burner operates as described below. The gas entering mixer 2 injects some amount of air necessary for combustion and is mixed therewith. The injection-type gas mixer 2 can be fixed to cylindrical casing 1 so that air-gas mixture enters casing 1 tangentially at low velocity. The air-gas mixture flux can acquire rotary motion, thereby moving circularly inside casing 1 and being reverberated from a cylindrical surface and the bottom of casing 1 . The air-gas mixture is directed to the center of the casing and then to emitter 4 . Thus, due to such attachment of mixer 2 to cylindrical casing 1 , more uniform flux distribution is obtained along the whole area of lower mesh 5 of emitter 4 . Such solution produces uniform flux distribution by the whole emitter area even at its large dimensions without special flux bumpers, which are used in the existing radiant gas burners [see for example, IR, Unified, Wind-Proof Gas Burner GIIV-3.65. Operation Manual. Kazan, 1989].
Casing 1 can accommodate several air-gas mixers 2 , e.g., to decrease overall dimensions. In one illustrative example, in order to prevent additional higher flow resistance during collision of separate air and gas fluxes, mixers 2 are fixed to casing 1 so as to ensure air-gas mixture input into the casing in one direction, clockwise or counter-clockwise ( FIG. 2 ).
Gas dissector 3 a , which is located along the pathway of air-gas mixture flux ahead of emitter 4 , allows increasing uniformity of air-gas mixture flux distribution by emitter 4 . Gas dissector 3 a is used to reflect part of the emission from emitter 4 which is directed towards burner bottom, as well as to heat air-gas mixture incoming for combustion. Gas dissector 3 a can be in the form of a ribbed grid (plate-type heat exchanger) comprising ribs 10 which are inclined to an upper grid plane 12 and a lower grid plane 14 . To promote reflection of the emission, edges of adjacent ribs can be in the same plane perpendicular to that of the grid ( FIG. 3 ). For example, an upper edge 16 of one rib can be connected by a plane 18 to a lower edge 20 of an adjacent rib, wherein plane 17 is perpendicular to grid planes 12 , 14 . Emission hitting the grid heats the ribs 10 and then the air-gas mixture flux passing through gaps 22 between the ribs of the grid is heated by convective heat transfer. This enables increasing heat to be released during gas combustion thereby raising burner performance.
To ensure reliable automatic ignition, aperture 8 can be provided in gas dissector 3 a and aperture 7 can be provided in casing 1 . A portion of the air-gas mixture entering into the space under gas dissector 3 a is directed to aperture 8 , since the gas dissector has low flow resistance. This same portion of the air-gas mixture passes through lower mesh 5 of emitter 4 and to aperture 7 , as upper mesh 6 of emitter 4 also possesses low flow resistance. An automatic igniter (not illustrated) can be fixed opposite aperture 7 outside the burner casing. Air-gas mixture combustion can occur in the space between meshes 5 and 6 of emitter 4 and the igniter can be positioned outside high temperature zone and thus will not interfere with a heat receiver located above emitter 4 .
To facilitate ignition, apertures 7 and 8 can have similar dimensions. Aperture 8 can be along a side of casing 1 and geometrical centers of the apertures 7 , 8 can be aligned including a distance therebetween.
The cross-section of the gas dissector grid is one of its defining parameters. On the one hand, it must be as small as possible to ensure high effectiveness of backscattered emission “trapping” and/or reflection, and on the other hand, it must be sufficiently large to assure low flow resistance to the incoming air-gas mixture. Thus, the maximum allowable flow resistance of the gas dissector grid provides a limitation to the increasing effectiveness of backscattered emission trapping.
The area of the grid surface contacting the air-gas mixture flux is another parameter. A larger contact surface enables more heat to be transferred from the heated grid to the air-gas flux. The grid ribs as shown and described provide for an increase to the contact surface area and an increase in heat transfer.
To increase heat transfer and its effectiveness in the gas dissector, one can use corrugated plates or rings to form a ribbed grid ( FIG. 4 ). An alternative gas dissector 3 b can be made in the form of coupled concentric cone rings 11 . To align upper and lower edges 17 , 21 of adjacent ribs in the same vertical plane 19 (between an upper grid plane 13 and a lower grid plane 15 ), a larger diameter of one ring can be equal to a smaller diameter of another adjoining ring. Thus, the gas dissector grid 3 b provides: low flow resistance to the incoming air-gas mixture 23 ;
maximum heat transfer during heat exchange between the emitter, the gas dissector, and the air-gas mixture flux; and, small dimensions.
Tables 1, 2 and 3 document operational parameters of a gas dissector grid 3 a , calculated for a radiant gas burner with specific heat capacity of 200 kW/m 2 , and an emitter's area of 0.01 m 2 . The grid material used was steel 12X18H9T.
The variable parameters included: grid thickness—h, rib inclination to grid plane—β, and rib thickness—δ. The calculated values included: real cross-section of the grid—m, hydrodynamic resistance—Δp (Pa), and heat transferred by convection—Q (W).
TABLE 1
(δ, β = const, h = var.)
Parameter
Value
h, mm
3
5
7
10
15
20
30
50
δ, mm
1
1
1
1
1
1
1
1
β, degrees
60
60
60
60
60
60
60
60
m
0.53
0.63
0.67
0.73
0.75
0.80
0.825
0.833
Δp, Pa
0.0370
0.0160
0.0110
0.0073
0.0049
0.0036
0.0026
0.0018
Q, W.
117
93
77
66
53
45
36
27
TABLE 2
(h, β = const, δ = var.)
Parameter
Value
δ, mm
0.5
1.0
1.5
2.0
2.5
3.0
3.5
h, mm
5
5
5
5
5
5
5
β, degrees
60
60
60
60
60
60
60
M
0.73
0.63
0.55
0.48
0.43
0.40
0.36
Δp, Pa
0.018
0.020
0.023
0.029
0.031
0.034
0.040
Q, W
88
88
88
89
88
90
90
TABLE 3
(δ, h = const, β = var.)
Parameter
Value
β, degrees
95
75
60
45
30
15
5
h, mm
5
5
5
5
5
5
5
δ, mm
1
1
1
1
1
1
1
M
0.30
0.54
0.63
0.56
0.39
0.19
0.07
Δp, Pa
1.000
0.070
0.020
0.015
0.025
0.085
0.600
Q, W
93
93
88
75
65
49
27
As seen from Table 1, increasing the grid thickness h leads to a larger real grid cross-section m on the one hand, and on the other hand, to a prominent reduction of heat Q transferred by the grid to the air-gas flux.
Table 2 shows that increasing grid rib thickness δ results in smaller real cross-section m of the grid while having little affect on the heat Q transferred by the grid to air-gas flux.
As seen from Table 3, decreasing rib inclination β to the grid plane leads to lower heat Q transferred by the grid to air-gas flux and significantly reduces the real cross-section m of the grid.
On the basis of the given data and with regard to the parameters of the gas dissector grid, one preferred embodiment for a grid configuration is as follows: a grid thickness less than or equal to 5.0 mm; a grid rib thickness less than or equal to 1.0 mm; and, a rib inclination to grid plane from about 45° to about 60°.
As described above, the gas mixture combustion occurs in metallic-mesh emitter 4 between meshes 5 and 6 . A greater portion of the heat during combustion is transferred to lower mesh 5 , which, when heated, becomes a source of IR. The upper mesh 6 intensifies the combustion process by returning part of the emission back into inter-mesh space 30 , and by being heated through the combustion process and emission from lower mesh 5 , thereby also becoming a source of IR radiation.
Mesh openings in the meshes, 5 , 6 attempt to meet contradictory objectives. On the one hand, they should be sufficiently large to provide low hydrodynamic resistance necessary for normal operation of the injector and, on the other hand, the size of lower mesh 5 openings should avoid flashback. For the upper mesh 6 , the total space of open flow area should be sufficiently large to provide low hydrodynamic resistance and at the same time it should return sufficient part of the emission from the lower mesh 5 to maintain combustion in between the meshes.
In one embodiment, the lower mesh openings (not illustrated) can have a maximum opening size of 0.8 mm and the upper mesh openings can have a minimum opening size of 1.5 mm.
The distance between the meshes can be about 8-10 times the size of the lower mesh openings and depends on the ratio of combustion rate and air-gas mixture flow velocity.
FIG. 5 shows a second embodiment of a radiant gas burner B 2 including casing 31 , consisting of two parts or segments. The casing has central 42 and peripheral 44 parts with one air-gas mixer 32 a , 32 b attached to each of them respectively. The burner B 2 also includes a gas dissector 33 and a metallic-mesh emitter 34 including a lower mesh 35 and an upper mesh 36 that form a biconvex lens having an inter mesh area 40 therebetween. A pair of apertures 37 , 38 can be positioned in the inter-mesh area and the dissector 33 , respectively.
In such burner design, the air-gas mixture can go to different parts of the casing both simultaneously and in turn. In other respects gas fuel combustion occurs as described for the burner design shown in FIG. 1 .
In one preferred version of the burner, a metallic-mesh emitter was used with square openings of 0.5×0.5 mm for the lower mesh and 3×3 mm for the upper one. Referring to table 4, comparative experiments were made using a conventional gas-plasma burner (No. 1), and burners with different geometry of a metallic-mesh emitter, namely, with parallel meshes (No. 2), meshes forming a biconvex lens (No. 3) and meshes forming a convex-concave lens (No. 4). All of the burners were of the same power −1.8 kW. The time to heat 2 kg of water to 90° C. was measured and the combustion products composition was determined. Instantaneous and total gas flow rate was monitored during the experiment. The same pan was used to heat water in each experiment. Combustion products composition was determined by gas analyzer TESTO-350. Table 4 gives the results of the comparative experiments.
TABLE 4
Total
Geometry of
CO
NO
gas flow rate
metallic
content,
content,
Time to heat 2 kg
during
mesh emitter
ppm
ppm
H 2 O to 90° C. (sec.)
experiment, 1
60
70-80
1124
37
No 1
17-20
8
1137
36.5
No 2
1-2
4-6
1159
35.5
No 3
10
4-5
1050
32.1
No 4
As seen from the data given in Table 4, the burner having a combustion zone formed in a biconvex lens (No. 3) resulted in a carbonic oxide content 1-2 ppm or 10 times less than that for a flat burner (No. 2). When heating the same amount of water with a burner in which the combustion space was a convex-concave lens (No. 4), gas flow rate was 12% less (32.1 compared to 36.5) than the burner with flat meshes (No. 2).
As described above, the stated problems can be solved by a radiant gas burner B 1 , B 2 having metallic mesh emitter 4 , 34 comprising lower 5 , 35 and upper 6 , 36 meshes forming an inner cavity 30 , 40 in the form of a lens (i.e. convex-concave, biconvex) with a radius of curvature of at least the burner's diameter and a thickness or width of at least 8-10 times the characteristic sizes of the lower mesh openings. The lower mesh having mesh size openings less than the upper mesh size. It is to be appreciated that the lower mesh 5 , 35 is in a convex orientation relative to the flow of air-gas mixture.
When the meshes are arranged such that the combustion area is an inner cavity in the form of a biconvex lens ( FIG. 5 ), part of the IR emission from the lower and upper meshes 35 , 36 is focused at the inter-mesh combustion area 40 , thereby intensifying the combustion process. This results in an increase to the gas combustion quality and a decrease in the carbonic oxide content in the combustion products.
While this invention has been described in conjunction with the exemplary embodiments outlined above, various alternatives, modifications, variations, improvements, and/or substantial equivalents, whether known or that are or may be presently unforeseen, may become apparent to those having at least ordinary skill in the art. Accordingly the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention. Therefore, the claims as filed and as they may be amended are intended to embrace all known or later developed alternatives, modifications, variations, improvements, and/or substantial equivalents. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of computer systems and, more particularly, to systems and methods of optimizing lock operations within computer systems.
2. Description of the Related Art
Computer systems can suffer severe performance degradation as a result of lock operations. In general, lock operations are associated with software locks which are used by computer systems to ensure that only one process at a time can access a resource, such as a critical region of memory. Throughout this specification, a memory region is used as an example of a resource associated with a lock. It is noted that the disclosed invention is equally applicable to other resources, such as an input/output location. A variety of locks have been implemented, ranging from simple spin-locks to advanced queue-based locks. Although simple spin-lock implementations can create very bursty traffic as described below, they are still the most commonly used software lock within computer systems.
Systems employing locks typically require that a given process perform an atomic operation to obtain access to a critical memory region. For example, an atomic test-and-set operation is commonly used. Generally speaking, an atomic operation is an indivisible operation. In other words, another process cannot access the lock between the test and set portion of the atomic operation. The test-and-set operation is performed to determine whether a lock bit associated withthe memory region is cleared and to atomically set the lock bit. That is, the test allows the process to determine whether the memory region is free of a lock by another process, and the set operation allows the process to acquire the lock if the lock bit is cleared.
Referring now to FIG. 1, a diagram illustrating a spin-lock implementation is shown. In a spin-lock implementation, if the test of the lock bit indicates that the memory region is currently locked, i.e. another process has acquired the lock, the requesters for the lock initiate a loop wherein the lock bit is continuously read until the lock bit is cleared, at which time the process reinitiates the atomic test-and-set operation.
Generally speaking, requesters are processes or other entities that seek to acquire the lock. Spin-locks may be implemented using either optimistic or pessimistic spin-lock algorithms. An optimistic spin-lock is depicted by the following algorithm:
______________________________________top:atomic.sub.-- test&set ;read-to-own transactionif failed begin while busy spin ;spin on read-to-share transaction goto top end______________________________________
For the optimistic spin-lock algorithm shown above, the process first performs an atomic test-and-set operation upon the lock bit corresponding to the memory region for which access is sought. If the atomic test-and-set operation fails, the process reads the lock bit in a repetitive fashion until the lock bit is cleared by another process. The process then reinitiates the atomic test-and-set operation. Generally speaking, a read-to-own (RTO) transactions requests write access to data and a read-to-share (RTS) transaction requests read access to data. It is noted that names other than RTO and RTS may be used to describe the concepts of acquiring read and write access to data.
A pessimistic spin-lock is depicted by the following algorithm:
______________________________________top:while busy spin ; spin on read-to-shareatomic.sub.-- test&set ; read-to-ownif failed begin goto topend______________________________________
For the pessimistic spin-lock algorithm, the process first reads the lock bit corresponding to the memory region for which access is sought in a repetitive fashion until the lock bit is cleared. When the process determines that the lock bit is clear in accordance with the read operation(s), the process performs an atomic test-and-set operation to lock and gain access to the memory region. If the test failed upon execution of the atomic test-and-set operation, the process again repetitively reads the lock bit until it is cleared.
In a shared memory computer system in which the requester performs a system bus, or global, transaction to test and set the lock, the above spin-lock algorithms create a large number of bus transactions. If the lock is not available, each requester attempting to acquire the lock bit continually performs global transactions until the lock becomes available. This large number of global transactions may adversely affect the performance of the computer system by using a large portion of the available bandwidth.
To reduce the number of global transactions performed by a spin-lock algorithm, the lock bit may be cached by each requester attempting to acquire it. In this manner, the repetitive reads to determine the state of the lock bit may be local transactions rather global transactions. While this may reduce the number of global transactions, the coherency traffic on the bus generated when the state of the lock bit changes may be unacceptable.
In a cached shared memory system, the read (or test) of the lock bit is treated as a read-to-share (RTS) operation. Since the atomic test-and-set operation includes a write, it is treated as a read-to-own (RTO) operation. The system will thus place the coherency unit containing the lock bit in a modified state in response to the atomic test-and-set operation.
For both the pessimistic and optimistic algorithms discussed above, when a memory region corresponding to a contended spin-lock is released, the owner writes to the lock to free it generating a RTO operation (1 bus transaction) which invalidates the line in the caches of all other devices. Therefore, all N spinning requesters subsequently miss and generate RTS transactions for the cache line containing the lock. The first requester to receive a data reply detects the free lock and generates an RTO transaction (1 bus transaction). Since the requester of each of the remaining RTS requests similarly receive an indication that the lock is free, each of these requesters also generates a RTO transaction (N-1 bus transactions). When the first RTO transaction is received, the requester issuing that transaction locks and gains access to the memory region. The test-and-set operations corresponding to the RTO requests of the remaining requesters therefore fail. The remaining N-2 requesters generate RTS transactions to cache the new lock bit (N-2 bus transactions).
Thus, the total number of transactions is potentially 3N-1 for the single transfer of a spin-lock from one requester to another (where N is the number of contenders for the lock). Due to this large number of transactions, the latency associated with the release of a lock until the next contender can acquire the lock is relatively high. The large number of transactions can further limit the maximum frequency at which ownership of the lock can migrate from node to node. Finally, since only one of the spinning requesters will achieve the lock, the failed test-and-set operations of the remaining processors result in undesirable RTO requests on the network. The coherency unit in which the lock is stored undesirably migrates from requester to requester, invalidating other copies. Network traffic is thereby further increased despite the fact that the lock is set.
Several lock designs to improve the performance of spin-locks have been devised, such as back-off locks and queue locks. In back-off locks, the requesters contending to acquire the lock implement a delay between attempts to acquire the lock. In this manner, the number of requesters contending for the lock at a given instance of time is reduced. The lock may be released and acquired by another requester before some requesters detect that the lock has been freed. Accordingly, the number of processes that attempt to acquire the lock when it becomes available is reduced. Low contention for the lock reduces the number of transactions when the lock changes state. The requesters that do not contend for the lock will generate a read-to-share transaction to read the new lock bit, but will not generate the read-to-share and read-to-own transactions to attempt to acquire the lock.
The delay implemented by a backup lock may be constant or variable. In a constant delay implementation, the requester delays a fixed time between attempted accesses to the lock. In a variable delay implementation, the duration of the delay may be different for different requesters. An exponential back-off lock is one example of variable delay back-off lock. In a exponential back-off lock, the delay implemented by the requester increases with each unsuccessful attempt to acquire the lock.
Back-off locks unfortunately may delay the acquisition of the lock. When a lock becomes available, a delay may occur before a process attempts to acquire the lock. This delay can increase the latency of a lock operation and reduce the performance of the computer system. Further, back-off locks can create fairness problems. Because each contending process has an equal chance of acquiring the lock, a process then has just begun waiting for the lock may be more likely to acquire the lock before a process that has been waiting for a long time. It is also theoretically possible for a waiting process to never acquire the lock.
Queue locks are another technique for reducing the overhead of lock operations. Referring now to FIG. 2, each requester for the lock is queued up behind earlier requesters. In this manner, only the process at the head the queue attempts to acquire the lock when it becomes available and generates bus transactions. Queue locks have the added benefit that they may be more fair than spin-locks because the earlier processes get the lock before processes that enter the queue later.
Unfortunately, in practice, queue locks have several disadvantages. For example, queue locks require space proportional to the number of queued requesters instead of the constant space required by spin-locks. This may make queue locks incompatible with some synchronization library interfaces. Further, if the process at the head of the queue is suspended or currently not running, the other processes behind the suspended process may not be able to acquire the lock. Still further, queue locks may be less efficient then spin locks if there is no contention for lock. Overhead may be incurred to check the queue to verify that no requesters are waiting to acquire the lock.
SUMMARY OF THE INVENTION
The problems outlined above are in large part solved by a probabilistic queue lock in accordance with the present invention. The probabilistic queue lock is a hybrid of a queue lock and a back-off lock. The probabilistic queue lock divides requesters for the lock into at least three sets. In one embodiment, the requesters are divided into the owner of the lock, the first waiting contender, and the other waiting contenders. The first waiting contender is made probabilistically more likely to obtain the lock by having it spin faster than the other waiting contenders. Because the other waiting contenders spin more slowly, the first waiting contender is more likely to be able to observe the free lock and acquire it before the other waiting contenders notice that it is free. The first of the other waiting contenders that determines that the previous first waiting contender has acquired the lock is promoted to be the new first waiting contender and begins spinning fast. A lock in accordance with present invention advantageously eliminates the delay in acquiring the lock present in back-off lock implementations, and eliminates the suspended process problems and variable space required by queue locks. At the same time, a lock implementation in accordance with the present invention advantageously reduces the number of transactions required to acquire the lock. Because only the first waiting contender is spinning fast on the lock, it is probable that only the first waiting contender will attempt to acquire the lock when it becomes available.
Broadly speaking, the present invention contemplates a method of synchronizing access to a resource in a computer system that includes a lock corresponding to the resource and a plurality of requesters that may attempt to access the resource, wherein the lock has at least three lock states. The method includes: a first requester of the plurality of requesters requesting acquisition of the lock; if the lock is in a free state, the first requester setting the lock to a held state and acquiring the lock; if the lock is in the held state, the first requester setting the lock to a wait state and spinning fast; and if the lock is in the wait state, the first requester spinning slow.
The present invention further contemplates a computer-readable storage medium comprising program instructions for synchronizing access to a resource in a computer system that includes a lock corresponding to the resource and a plurality of requesters that may attempt to access the resource, wherein the lock has at least three lock states. The program instructions are operable to implement the steps of: a first requester of the plurality of requesters requesting acquisition of the lock; if the lock is in a free state, the first requester setting the lock to a held state and acquiring the lock; if the lock is in the held state, the first requester setting the lock to a wait state and spinning fast; and if the lock is in the wait state, the first requester spinning slow.
The present invention still further contemplates a method of synchronizing access to a resource in a computer system that includes a lock corresponding to the resource and a plurality of requesters that may attempt to access the resource, wherein the lock has at least four lock states. The method includes: a first requester of the plurality of requesters requesting acquisition of the lock; if the lock is in a free state, the first requester setting the lock to a first held state and acquiring the lock; if the lock is in the first held state, the first requester setting the lock to a second held state and spinning fast; if the lock is in the second held state, the first requester setting the lock to a wait state and spinning medium; and if the lock is in the wait state, the first requester spinning slow.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
FIG. 1 is a diagram illustrating a spin-lock implementation;
FIG. 2 is a diagram illustrating a queue lock implementation;
FIG. 3 is a block diagram of a multiprocessor computer system including a shared memory according to one embodiment of present invention;
FIG. 4 is a diagram illustrating a probabilistic queue according to one embodiment of the present invention;
FIG. 5 is a flowchart illustrating the operation of a lock algorithm according to one embodiment of the present invention;
FIG. 6 is a flowchart illustrating the operation of a lock algorithm with three locks states according to one embodiment of the present invention; and
FIG. 7 is a flowchart illustrating the operation of a lock algorithm with four lock states according to one embodied in the present invention.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 3, a block diagram of a multiprocessor computer system including a shared memory according to one embodiment of the present invention is shown. Computer system 300 includes three nodes (312, 314 and 316) and a memory 336 interconnected by data communication bus 334. Node 312 includes a processor 316, a cache 318 and a communication interface 320. Node 314 includes a processor a 322, cache 324 and a communication interface 326. Node 316 includes a processor 328, a cache 330 and a communication interface 332. Nodes 312-316 and components within these nodes are conventional devices known to those of ordinary skill in the art. Memory 336 includes a plurality of storage locations including a memory location 338 and a lock 340. Communication interfaces 320, 326 and 332 provide an interface between data communication bus 334 any other components of the nodes. Memory 336 is a conventional storage device such as a random access memory (RAM).
Lock 340 may be used to synchronize access to memory location 338. Prior to accessing memory location 338, a node reads a lock state stored in lock 340 to determine whether another node (or another process) is accessing memory location 338. Nodes, processors, processes, or any other device that attempt to access memory location 338 are referred to as requesters. For example, multiple processors in a multiprocessing computer system or multiple processes executing on the same processor may request access to memory location 338.
If the lock is in a free state when a requester reads the state of the lock, i.e. no other requester is accessing memory location 338, then the requester may acquire the lock and access the memory location. When the requester acquires the lock, the requester may set the lock to a held state to indicate to other requesters that the memory location is being accessed. If the lock is in a held state when a requester reads the state of the lock, i.e. another requester is accessing memory location 338, the requester may wait until the lock becomes available to access memory location 338.
When a node acquires lock 340, it may cache the lock. Once the lock is cached, accesses to test the state of the lock are local accesses. If the state of the lock is modified by another node, the cached copy may be invalidated. When a requester detects that its cached copy is invalid (e.g., detects a cache miss), a requester may read the state of the lock from memory 336 to determine if it may access the memory location. It is noted, that both snooping or directory-based coherency protocols may be implemented.
Turning now to FIG. 4, a diagram illustrating a probabilistic queue according to one embodiment of the present invention shown. The requesters attempting to acquire a lock are divided into three categories. The first device that requests the lock becomes a lock owner 412. The first requester subsequent to the lock owner that attempts to acquire the lock becomes the first waiting contender 414 for the lock. The requesters subsequent to the first waiting contender become other waiting contenders 416 for the lock. In one embodiment, first waiting contender 414 spins fast on the lock. In this embodiment, first waiting contender 414 is in a tight loop testing the state of the lock to determine when the lock becomes available. In one embodiment, other waiting contenders 416 spin slow on the lock. In other words, other waiting contenders 416 implement a delay between attempts to acquire the lock.
When the lock becomes available, there is a high probability that first waiting contender 414, which is spinning fast, will be the first requester to test the state of the lock and acquire the lock. Accordingly, with high probability, there will be low contention for the lock when it becomes available. As discussed above, low contention for the lock reduces the coherency traffic when the lock becomes available. Additionally, because first waiting contender 414 is spinning fast on the lock, the delay before it acquires the lock is minimized. Still further, if the first waiting contender is unable to acquire the lock (e.g., the process is suspended), an other waiting contender 416 will read and acquire the lock after some delay.
Turning now to FIG. 5, a flowchart illustrating the operation of a lock algorithm according to one embodiment of the present invention is shown. In the illustrated embodiment, the lock may be in one of three lock states. In one embodiment, the state of the lock is determined by a value stored to the lock. The first state is called the "free" state and indicates that no requester has acquired the lock. The second state is called the "held" state and indicates that a requester has acquired the lock, but there is no first waiting contender. The third state is called the "wait" state and indicates that a requester has acquired the lock and a first waiting contender is established. In one embodiment, the current state of the lock is encoded and stored in a single lock location. Accordingly, the storage space required to implement a probabilistic queue may be as little as two bits. The unlock operation, or releasing the lock, is accomplished by simply writing zero to the lock.
In one embodiment, each requester runs a lock algorithm similar to the algorithms discussed below. In step 512, a requester tests the state of the lock. In one particular embodiment, testing the state of the lock involves reading the current state of the lock and comparing it to possible lock states. In step 514, it is determined whether the lock is in the free state. If the lock is in the free state, then in step 516 the lock state is set to the held state. In step 518, the requester accesses the memory location corresponding to the lock. In step 520, the requester sets the lock to the free state. The lock is then available for another requester to acquire.
If in step 514 the lock is not in the free state, then in step 522 it is determined whether the lock is in the held state. If the lock is in the held state, the requester becomes the first waiting contender. In step 524, the lock state is set to the wait state. In step 526, the requester spins fast. As discussed above, spinning fast may involve waiting in a tight loop for the state of the lock to change. When the state of the lock changes, execution continues at step 512.
If in step 522 the lock is not in the held state, then in step 528 it is determined whether the lock is in the wait state. If the lock is in the wait state, then the requester becomes an other waiting contender. In step 530, the requester spins slow. As discussed above, spinning slow involves delaying a predetermined duration prior to testing the state of the lock. When the requester detects that the state of the lock is modified, execution continues at step 512.
Because the first waiting contender is spinning at a faster rate than the other waiting contenders, it is highly probable that the first waiting contender will detect the change of state of the lock before the other waiting contenders. When the first waiting contender detects the change in state, it will attempt to acquire the lock. In most instances, the first waiting contender will acquire the lock before any of the other waiting contenders detect the change of state. The first other waiting contender to detect the change of state will test the lock and become the first waiting contender. The subsequent other waiting contenders will test the lock and determine that the lock is in the wait state and not attempt to modify the lock. It is possible that one or more of the other waiting contenders may detect the change of state of the lock before or soon after the first waiting contender. In this situation, two or more requesters may contend for the lock.
Turning now to FIG. 6, a flowchart illustrating the operation of a lock algorithm with three locks states according to one embodiment of the present invention is shown. FIG. 6 illustrates a probabilistic lock algorithm. In one embodiment, each requester executes the probabilistic lock algorithm to synchronize access to a memory location that corresponds to a lock. A similar algorithm may be used to synchronize access to other memory locations. In the illustrated embodiment, there are three possible lock states: free, held and wait. Each state may be assigned a unique encoding. In the illustrated embodiment the encoding for the free state is zero, the encoding for the held state is one, and the encoding for the wait state is two.
In step 612, the current state of the lock is tested. In one embodiment, testing the current state of the lock involves reading the lock state and comparing the lock state to the possible lock states. In step 614, it is determined whether the lock state is zero, which corresponds to the free state. If the lock state is zero, then in step 616 the lock state is set to one, which corresponds to the held state. In step 618, the requester accesses the corresponding memory location. In step 620, the requester sets the lock state to zero. Accordingly, if the lock state is free, the requester acquires the lock, accesses the corresponding memory location and frees the lock.
In one embodiment, an atomic operation is used to test and set the lock state. In one embodiment, an atomic compare and set (CAS) operation is used to read, compare and set the lock value. For example, the command "cas lock, 0, 1" reads the lock value and sets the lock value to one if the lock value is zero. If the lock value is not zero, the lock value is not changed. Steps 612, 614 and 616 may be accomplished by the above CAS command. It is noted, the other atomic commands may be used.
In step 622, it is determined whether the lock value is still zero. This step handles the case were the lock value changes back to zero after step 614. If the lock value is zero, execution continues at step 612. Alternatively, if the lock value is not zero, then in step 624, it is determined whether the lock value is two, which corresponds to the wait state. If the lock value is two, then in step 626 the requester begins to spin slow. As discussed above, spinning slowly includes waiting a predetermined duration prior to attempting to acquire the lock again. After the predetermined duration, in step 640 it is determined whether the lock value is two. If the lock value is not two, then execution continues at step 622. Alternatively, if the lock value is not two, then execution continues at step 626 and the requester continues to spin. In an alternative embodiment, an optimistic approach may be used and step 628 may be performed prior to step 626. In other words, the state of lock may be checked prior to the first delay.
If in step 624 the lock value is not two, then in step 630 the lock value is tested. In step 632, it is determined whether the lock value is one. If the lock value is not one, then execution continues its step 622. If the lock value is one, then in step 634 the lock value is set to two. In step 636, the requester spins fast. As discussed above, in one embodiment, spinning fast is a tight loop reading the state of the lock value. In the illustrated embodiment, the tight loop includes 638 and 640. In step 640, it is determined whether the lock value is zero. If the lock value is not zero, then execution continues at step 636. If the lock value is zero, then execution continues at step 612. In one embodiment, steps 630, 632 and 634 are performed by an atomic command. In one particular embodiment, the command "cas lock, 1, 2" reads the lock value and sets the lock value to 2 if the lock value is 1.
It is noted that the above flowchart can result in multiple first waiting contenders. This anomaly does not affect the correctness of the lock because the exclusivity of the lock is guaranteed. In other words, two requesters cannot acquire the lock concurrently. To prevent this anomalous condition would require more overhead in the unlock operation which may slow down the algorithm. In a preferred embodiment, the anomalous condition is maintained because it does not affect the correctness of the lock. The anomalous condition may occur when there is a first waiting contender and a plurality of other waiting contenders. If the lock owner frees the lock and an other waiting contender acquires the lock prior to the first waiting contender, the other waiting contender will set the lock value to one. A second other waiting contender may then detect that the lock is set to one, set the lock to two, and become another first waiting contender before the original first waiting contender observes that the lock has changed state. For this anomaly to occur two unusual sets of conditions must occur. First, it is highly probable that the first waiting contender, which is spinning fast, will detect and acquire a lock before an other waiting contender, which is spinning slow. For an other waiting contender to acquire the lock, it would have to perform steps 628, 622, 624, 630, and 632 before the first waiting contender performs step 640. Even if an other waiting contender does acquire the lock, a second other waiting contender would subsequently has to perform steps 628, 622, and 624 before the first waiting contender performs step 640. This set of conditions is very unlikely to occur and as noted above does not effect the correctness of the lock.
The total number of bus transactions required to transfer the lock in the most likely case of the probabilistic queue is N+3. The number transactions discussed below assumes a snooping coherency management protocol. It is noted that the present invention is also applicable to other coherency management protocols, such as a directory-based coherency management protocols. When a lock owner (R0) frees the lock, it invalidates all the other requester's cached copies of the lock (one invalidate bus transaction). With high probability, the first waiting contender (R1) detects the changed state, for example by a cache miss, and tests the lock (one read-to-share bus transaction). The first waiting contender (R1) then writes to its cached copy of the lock and cause a second invalidation of the cached copies of the locks in other waiting contenders (one invalidate bus transaction). If the slow spin loop is sufficiently long, the other requesters receive this second invalidation before the requesters test the lock so the second invalidation is redundant to the first invalidation. The first of the other waiting contenders (R2) to detect the change in state reads the value of the lock (one read-to-share bus transaction). Other waiting contender (R2) then writes to the lock to become the first waiting contender (one read-to-own bus transaction). This causes a third invalidation of the lock (one invalidate bus transaction). If the slow spin loop is sufficiently long, the other requesters receive this third invalidation before they test the lock and the third invalidation is redundant to the first two invalidations. The remaining other waiting contenders subsequently generate cache misses and read the state of the lock (N-2 read-to-share bus transactions). Because the lock is in the wait state, these other waiting contenders do not generate writes to the lock when they read the lock state. If one or more other waiting contenders test the lock during the transfer, these other waiting contenders may generate additional bus transactions, which may increase the number of transactions, but not substantially.
Turning now to FIG. 7, a flowchart illustrating the operation of a lock algorithm with four lock states according to one embodiment of the present invention is shown. In the illustrated embodiment, the lock algorithm includes four lock states. In addition to the three lock states discussed above, this embodiment includes a second held state. A second waiting contender is configured to spin slower than the first waiting contender and faster than the other waiting contenders. It is highly likely that the second waiting contender will become the first waiting contender when the first waiting contender acquires a lock. The lock stores an encoded value representing the current state of the lock. The encoding for the held state is zero, the encoding for the first held state is one, the encoding for the second held state is two, and the encoding for the wait state is three.
In step 712, the current state of the lock is tested. In step 714, it is determined whether the lock value is zero, which corresponds to the free state. If the lock value is zero, then in step 716 the lock value is set to one, which corresponds to the first held state. In step 718, the requester accesses the corresponding memory location. In step 720, the requester sets the lock state to zero. Accordingly, if the lock state is free, the requester acquires the lock, accesses the corresponding memory location and frees the lock. Steps 712, 714 and 716 may be accomplished by an atomic command.
In step 722, it is determined whether the lock value is still zero. This step handles the case were the lock value changes back to zero after step 714. If the lock value is zero, execution continues at step 712. Alternatively, if the lock value is not zero, then in step 724 it is determined whether the lock value is three. If the lock value is three, then in step 726 the requester begins to spin slow. After a predetermined delay, in step 728 it is determined whether the lock value is three. If the lock value is not three, then execution continues at step 722. Alternatively, if the lock value is three, then execution continues at step 726 and the requester continues to spin.
If in step 724 the lock value is not three, then in step 730 the lock value is tested. In step 732 it is determined whether the lock value is two. If the lock value is two, then in step 734 the lock value is set to three. In step 736, the requester spins medium. A requester that spins medium implements a delay prior to attempting to acquire the lock. The delay is shorter than the delay for a slow spinning requester. In step 738, it is determined whether the lock value is three. If the lock value is three, then execution continues at step 736. If the lock value is not three, then execution continues at step 712. In one embodiment, steps 730, 732 and 734 are performed by an atomic command.
If in step 732 the lock value is not two, then in step 740 the lock value is tested. In step 742, it is determined whether the lock value is one. If the lock value is not one, then execution continues at step 722. If the lock value is one, then in step 744 the lock value is set to two. In step 746, the requester spins fast. In step 750, it is determine whether the lock value is zero. If the lock value is not zero, then execution continues at step 746. If the lock value is zero, then execution continues at step 712. In one embodiment, steps 740, 742 and 744 are performed by an atomic command.
In other embodiments, additional held states may be included. For example, the present invention may be implemented with an owner, a first waiting contender, a second waiting contender, a third waiting contender and one or more other waiting contenders.
Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications. | 4y
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BACKGROUND OF THE INVENTION
Single or multipin terminal connectors of the type to which the present invention relates are commonly used to connect one or more conductors. Accordingly, the terminal connector assembly usually has for each pin to be connected, a clamped connection for the conductor which is connected in a conductive manner via a contact element to at least one connecting contact. The connecting contact is the vehicle for connecting the terminal connector to a device to which the conductor is to be associated. For example, a terminal connector is mounted on a circuit board wherein the conductive pathways are connected to the connecting contacts of the terminal connector.
There are various types of clamp connections for the presently known terminal connectors. For example, there are screw-type terminal contacts, installation displacement contacts and spring-type terminal contacts. The connecting contacts in these known assemblies can be designed as plug-type contacts, solder contacts or the like. Presently known terminal connector designs are technically relatively easy to produce and to assemble since assembly is usually associated with a permanent, predetermined orientation of the clamp connections and the connecting contacts. Specifically, this means the terminal connector can be inserted and connected only with the orientation permanently predetermined by the arrangement of the clamp connections and the connecting contacts. This technique has certain disadvantages and drawbacks. For example, a separate type of terminal connector is therefore required for each different concrete application. In the case of the convention terminal connectors; however, a greater degree of versatility is associated with a more complicated design which in turn means higher production and assembly costs.
SUMMARY OF THE INVENTION
With the foregoing in mind, it is an object of the present invention to provide a terminal connector assembly characterized by novel features of construction and arrangement which can be produced and assembled very economically at low cost and which provides a high degree of versatility with respect to orientation and use. To this end, the assembly comprises a contact element made of a one-piece stamping of sheet material of a predetermined shape to form springs for at least one clamped connection and at least one connecting contact and means mounting the contact element in a positive form locking manner in the housing. More specifically, the goal of the present invention is to provide a terminal connector wherein each pin to be connected consists of a contact element which can be stamped as one piece out of sheet metal. Predetermined sections of the edges of the stamped metal part are then bent upward to form springs both for the clamp connections for the conductors and also for the connecting contacts. By this construction, the contact element can be inserted loosely and supported in the housing in a positive form locking manner.
The contact elements are extremely easy to manufacture because only a stamping and bending procedure is required in the formation of the complete contact element including both the clamped connection and the connecting contact. Further, the assembly of the terminal connector is also greatly simplified because the only step necessary is to insert the contact element loosely in the housing of the terminal connector. It as been found that in accordance with the present invention, the production and assembly of the terminal connector are particularly suitable for high speed automated assembly procedures.
Because the clamped connections and connecting contacts can be bent upward around the entire periphery of the stamped metal part forming the contact element, there is great freedom in terms of the number and arrangement of the clamped connections and connecting contacts, a freedom which can be exploited without leading to an increase in production and assembly costs. By distributing several clamped connections and connecting contacts around the periphery of the contact element and by arranging them in different plug-in directions, great flexibility is obtained with respect to the orientation of the terminal connector. The same type of terminal connector can thus be used for different applications. Production costs can therefore be lowered as a result of high-volume production, and inventory costs can be reduced because of the smaller number of different types which must be kept in stock.
There are additional specific features of the invention which provide certain functional and manufacturing advantages. For example, in accordance with one embodiment of the present invention, the terminal connector is constructed from individual modules, each of which represents one pin to be connected. This produces a cost reduction, since only one standard module is produced and terminal connectors with any desired number of pins can be assembled from the modules.
In accordance with another feature of the present invention, the housing of each module consists of a housing plate and a housing frame which are of a configuration to form a receptacle cavity for receiving the contact element and where the configuration is such to hold the contact element in a positive, form-locking manner. The open side of the frame of the module is sealed off by either the housing plate of the adjacent module or by a cover.
In accordance with another feature of the present invention, the clamp connection preferably have a clamping spring designed like a barb to ensure a simple and reliable connection of the conductors to the clamp connection. When the stripped conductor is pushed in, the clamping spring can be easily pushed aside. However, because the edge of the free end of the clamping spring penetrates the conductor, the spring prevents the conductor from being pulled back out. A slide piece supported in the housing permits release of the clamp connection when it is desired to remove the conductor.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the present invention and various features and details of the operation and construction thereof are hereinafter more fully set forth with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of a first embodiment of a module of the terminal connector;
FIG. 2 shows a diagram corresponding to FIG. 1, in which the clamped connection is being released;
FIG. 3 shows a perspective view of the contact element of the first embodiment;
FIG. 4 shows the stamped sheet-metal part, which is bent to form the contact element of FIG. 3;
FIG. 5 shows a perspective view of the design of a multi-pin terminal connector assembled from the modules of the first embodiment;
FIG. 6 shows a first way in which the terminal connector of FIG. 5 can be oriented;
FIG. 7 shows a second way in which the terminal connector of FIG. 5 can be oriented;
FIG. 8 shows a third way in which the terminal connector of FIG. 5 can be oriented;
FIG. 9 shows a second embodiment of the terminal connector;
FIG. 10 shows a third embodiment of the terminal connector; and
FIG. 11 shows a fourth embodiment of the terminal connector.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
There are various embodiments of the present invention illustrated and described herein and for sack of simplicity, the parts which are the same in each embodiment are designated by the same reference numerals and are explained only once in conjunction with the first exemplary embodiment of the present invention which is illustrated in FIGS. 1-8, inclusive.
Referring now to the drawings, there is shown in FIGS. 1-8, inclusive, a first embodiment of connector assembly in accordance with the present invention. The terminal connector assembly consists of a plurality of individual modules, each of which holds one of the pins to be connected. Thus the terminal connector assembly can be designed as a single pin connector or as a multi-pin connector with any desired number of pins.
Considering now the terminal connector assembly more specifically, and with respect to FIG. 1, there is shown an individual module M comprising a flat, essentially rectangular box-like housing 10 including a flat essentially rectangular housing plate 11 and a housing frame 12 projecting peripherally beyond the housing plate 11. Housing plate 11 and housing frame 12 may be molded from plastic as a single unitary piece. Housing frame 12 extends all the way around the periphery of housing plate 11 and comprises first and second slide ways 12a, 12b, and front and rear end wall 12c and 12d, respectively. By this arrangement, the housing 10 forms a receptacle C which is enclosed by housing plate 11 and housing frame 12 and which is open on the side of the frame opposite housing plate 11.
Positioning pegs 13 project from the interior surface of housing plate 11 as at 11a. The height H of pegs 13 looking in a direction perpendicular to the housing plate 13 is generally the same as the height H1 of housing frame 12. A support surface 14 is formed at the center of end wall 12c which projects into the interior of housing 10. Between first side wall 12a, support surface 14, end wall 12c is penetrated by a first insertion opening 15a. A second insertion opening 15b is provided between second side wall 12b and support surface 14 and end way 12c. In the area of insertion openings 15a, 15b, first and second slide pieces 16a, 16b, respectively, are arranged as mirror images of each other and extend along the sides of support surface 14. Slide pieces 16a, 16b are mounted in the housing in a manner so that they can slide in the direction perpendicular to end wall 12c. Each slide piece has a wedged-shaped bevel B at the ends thereof pointing into the housing 10. Slide pieces 16a, 16b fill up approximately half of the open area of the insertion openings 15a, 15b on the side of the opening facing away from support surface 14.
Bordering rear wall 12d, first side wall 12a is penetrated by a first plug-in opening 17a, second side wall 12b by a second plug-in opening 17b. Rear wall 12d is penetrated in the center by a third plug-in opening 18. First side wall 12a is penetrated in its central area by a first test opening 19a, second side wall 12b by a second test opening 19b, located in the middle as a mirror image of the first test opening.
Housings 10 of the individual modules of the terminal connector can be combined as shown in FIG. 5. For this purpose, housing frame 12 has snap-fastener holes 20 in its open side. On the side closed by housing plate 11, housing frame 12 has snap-fastener pegs 21, each of which is aligned to and lines up with a snap-fastener hole 20. In addition, snap-fastener holes 22 are formed in the exposed ends of positioning pegs 12. Snap-fastener pegs 23 are arranged in correspondence with them on the external surface of housing plate 11. When the individual modules are combined to form a multi-pin terminal connector, snap-fastener pegs 21 engage in their assigned snap-fastener holes 20 in housing frame 12, and snap-fastener pegs 23 engage in snap-fastener holes 22 in the positioning pegs, so that the individual housings 10 are locked together.
The open side of the frame of housing 10 is sealed off by housing plate 11 of the neighboring housing 10. The open side of the frame of the last housing 10 is sealed off by a housing cover 24, which has the same shape as housing plate 11 and has correspondingly arranged snap-fastener pegs 21, 23.
A contact element 30, shown separately in FIG. 3, is inserted into each housing 10. Contact element 30 is laid loosely in the receptacle cavity of housing 10 and is held in a positive, form-locking manner in housing 10. This positive positioning, which prevents displacement in the plane of housing plate 11, is provided by housing frame 12, support surface 14 and positioning peg 13. In the direction perpendicular to housing plate 11, contact element 30 is held in a positive, form-locking manner between housing plate 11 and housing plate 11 of adjacent housing 10 or housing cover 24.
Contact element 30 may be produced as a cone-piece part, stamped out of sheet metal. For this purpose, a piece of sheet metal is first stamped out as illustrated in FIG. 4. The edges of the stamped metal part are bent upward in certain sections to form the elastic clamped connections and the connecting contacts as illustrated in FIG. 3.
A contact element 30, shown separately in FIG. 3, is inserted into each housing 10. Contact element 30 is laid loosely in the receptacle cavity of the housing 10 and is held in a positive form-locking manner in housing 10. This positive positioning which prevents displacement in the plane of housing plate 11 is provided by housing frame 12, support surface 14 and positioning peg 13. In the direction perpendicular to housing plate 11, contact element 30 is held in a positive, form-locking manner between housing plate 11 and housing plate 11 of adjacent housing 10 or housing cover 24.
Contact element 30 has a base plate 31, around which the edges to be bent up are formed. A clamping spring 32 is formed in the middle of the side edge of base plate 31 facing end wall 12c. The clamping spring 32 has a first sidepiece 32a, a second sidepiece 32b, representing mirror images of each other. When contact element 30 is inserted into housing 10, the area of clamping spring 32 connected to base plate 31 rests against support surface 14 of housing frame 12. Shanks 32a, 32b project into the area behind insertion openings 15a, 15b, bending inward from end wall 12c into the interior of the housing. Because of the elastic properties of the sheet metal, the free ends of stamped sidepieces 32a, 32b thus holds the slide pieces in their end position, i.e., pushed against end wall 12c.
Contact springs 33a, 33b are stamped out on the edges of base plate 31 facing side wails 12a, 12b and then bent up. Each contact spring 33a, 33b has a support section 34a, 34b connected to base plate 31, which because of its direct connection to base plate 31, has relatively high rigidity. Following after support sections 35a, 35b are free, stamped-out compression sections 35a, 35b which are elastic and extend toward the rear. Compression sections 35a, 35b are bent inward, as mirror images of each other like snail shells over more than half the circumference of a circle, so that their free ends rest elastically against each other.
Two support surfaces 36a, 36b are formed next to each other on the edge of base plate 31 facing rear wall 12d of housing 10 and are bent up at a right angle from the plane of base plate 31. Support surfaces 36a, 36b leave a space free in the middle, which after insertion of contact element 30, lines up with third plug-in opening 18 in rear wall 12d of housing frame 12. Compression sections 35a, 35b of contact springs 33a, 33b rest with elastic force against support surfaces 36a, 36b.
Finally, base plate 31 has two positioning holes 37 stamped into it through which positioning pegs 13 of housing 10 pass when contact element 30 is inserted into housing 10.
FIG. 1 shows contact element 30 after it has been inserted into housing 10. Positioning pegs 13 are engaged in positioning holes 37 to hold contact element 30 in housing 10 in a positive form-locking manner. Clamping spring 32 rests against support surface 14 of housing frame 12. First contact spring 33a rests with its support section 34a against the first side wall 12a. Second contact spring 33b rests with its support section 34b against second side wall 12b. Free sidepieces 32a, 32b rest elastically against support sections 34a, 34b and side walls 12a, 12b. Support surfaces 36a, 36b rest against rear wall 12d. Free compression sections 35a, 35b of contact springs 33a, 33b rest elastically against support sections 34a, 34b and also rest elastically against each other between positioning pegs 13. The elastic force exerted by compression sections 35a, 35b against support sections 34a, 34b is absorbed by these support sections 34a, 34b and by rear wall 12d.
The clamped connections formed by sidepieces 32a, 32b of clamping springs 32 and support sections 34a, 34b of contact springs 33a, 33b serve to connect the conductors. Stripped ends 50a, 50b of conductors 50 are pushed through insertion openings 15a, 15b. Conductors 50a, 50b thus arrive between support sections 34a, 34b and inward-bent sidepieces 32a, 32b of clamping spring 32. Shanks 32a, 32b and 32b are pushed by conductors 50a, 50b away from support sections 34a, 34b so that conductors 50a, 50b become clamped between sidepieces 32a, 32b and support sections 34a, 34b so that conductors 50a, 50b become clamped between sidepieces 32a, 32b and support sections 34a, 34b and thus held in conductive contact with contact element 30. Conductor 50 cannot be pulled out of the clamped connection or slide free by itself because the edge of the free end of sidepieces 32a, 32b rests under elastic pressure against the outside surface of conductors 50a, 50b. When a tensile force is exerted on a conductors 50a, 50b, the edge of the free end of sidepiece 32a, 32b digs itself into conductor 50a, 50b and holds it with a barb-like action. Increasing the tensile force leads to an increase in the clamping effect between sidepieces 32a, 32b and support sections 34a, 34b.
When it is desired to release conductor 50 from the clamped connection, a suitable tool, e.g., a screwdriver 51, is used to push the associated slide piece 16a inward, as shown in FIG. 2. The wedge-shaped inner end of slide piece 16a then presses against bent sidepiece 32a of clamping spring 32 and presses this inward away from support section 34a, conductor 50a. The edge of the free end of sidepiece 32a is thus lifted from conductor 50a so that the conductors can then be easily pulled out.
FIGS. 6-8 show how the terminal connector can be connected to a device to be connected, i.e., a circuit board 52. For this purpose, circuit board 52 has plug pins 53 which are spaced in a manner corresponding to the spacing between the modules M of the terminal connector. In the illustration of FIG. 6, the terminal connector is set down from above onto circuit board 52, so that plug pins 53 are able to pass through the lower, second, plug-in openings 17b and into the connecting contacts, which are formed by compression section 35b and second support surfaces 36b. The curvature of compression sections 35b makes it possible for plug pins 53 to be inserted and pulled out. The elastic property of compression sections 35b ensures that a reliable contact will be made between compression sections 35b and support surfaces 36b and thus with contact element 30. Conductors 50 extend into the terminal connector in a plane parallel to the plane of circuit board 52.
FIG. 7 shows a different orientation of the terminal connector. Here, the terminal connector is mounted on circuit board 52 in such a way that plug pins 53 pass through the third plug-in openings 18 between compression sections 35a, 35b which are resting against each other. Here also, the curvature of pressure sections 35a, 35b guarantees that pins 53 can be plugged in easily and also easily removed. The elastic properties of compression sections 35a, 35b ensure good contact between pins 53 and contact element 30. In this orientation of the terminal connector, conductors 50 can be brought to circuit board 52 in the direction perpendicular to the plane of the board.
FIG. 8, shows an arrangement in which plug-in pins 53 project downward from the circuit board and the terminal connector is correspondingly mounted on plug-in pins 53 by the connecting contacts formed by compression sections 35a, support surfaces 36b.
Access to support sections 34a, 34b from the outside is possible through test openings 19a, 19b. Thus, the tip of a test probe can be passed through a test opening 19a, 19b to touch contact element 30 to test the voltage at contact element 30 or to tap an electrical signal being carried across the terminal connector.
The exemplary embodiment shown makes it possible to connect two conductors 50a, 50b to the same connecting pin formed by contact element 30. It is obvious that it is not necessary for two conductors to be connected to the connecting pin. If desired, it is also possible for only one conductors to be connected either to clamped contact 33a, 34b or to clamped contact 33b, 34b.
In addition, it is easy to see that the mirror-symmetric design of the upper and lower halves of the exemplary embodiment is not mandatory. The terminal connector can also be designed with only one of these halves. In that case, for example, the connecting contact formed between compression section 35 and support surface 36 can be contacted both via first plug-in opening 17a, also via second plug-in opening 17b.
FIG. 9 shows a second exemplary embodiment of the terminal connector.
In this embodiment, first sidepiece 32a of clamping spring 32 rests against only one support section 34a of first contact spring 33a. A compression section 35a of contact spring 33a is not provided. Second sidepiece 32b of clamping spring 32 rests against a support section 34b of second contact spring 33b, which also has no compression section 35b. Terminal pins 38 are formed on support section 34b to serve as the connecting contact of the terminal connector. These pins pass through holes in second side wall 12b and can be for example inserted into holes 54 in a circuit board 52.
In the exemplary embodiments of FIGS. 9 and 10, the terminal connector is intended to be soldered to a circuit board. According to FIG. 9, conductors 50 extend parallel to the plane of circuit board 52, whereas, according to FIG. 10, they are perpendicular to the plane of circuit board 52. Connecting contacts designed to act as plug receptacles are not provided in these embodiments.
FIG. 11 shows and exemplary embodiment in which the connecting contacts act as receptacles for plugs and can also be soldered. First contact spring 33a is designed with a compression section 35a, which rests elastically against a support surface 36. Thus, a plug-in connecting contact is formed between compression section 35a, support surface 36, into plug pins can be inserted. Second contact spring 32b is designed with only one support section 34b, which is provided by terminal pins 38.
In this embodiment, terminal pins 38 of the terminal connector can be inserted into a first circuit board 52, for example, and soldered to it. A second circuit broad 52 with plug pins can then be plugged from above into plug-in connecting contacts 35a, 36. Thus, a sandwich arrangement of circuit boards 52 is possible, where the terminal connectors being about both the mechanical and the electrical connection between the circuit boards.
Even though particular embodiments of the invention have been illustrated and described herein, it is not intended to limit the invention and changes and modifications may be made therein within the scope of the following claims. | 4y
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The research leading to the present invention was supported in part by the U.S. Government, specifically by the Veterans Administration and NIH Grant No. IROI EYO5800.
BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to a method and composition for diagnosis of HSV infections in animals and humans.
2. Prior Art
Herpes Simplex infections (HSV) in humans and animals are exceedingly common. Approximately 75% of the adult population has been infected with HSV-1 and some 30-50% experience recurrent oral cold sores as the sole manifestation of infection with the remainder having no symptoms. Similarly, although HSV-2 or genital herpes is extremely prevalent, and also recurs frequently; its major significance is less in terms of physical discomfort and more in terms of emotional upset and interference with sex life. However, a small number of patients develop life threatening encephalitis or disseminated infection. Despite sophisticated instrumentation, HSV encephalitis cannot be reliably diagnosed without a brain biopsy and disseminated infection in the newborn is likewise undiagnosable unless skin infection occurs, which would be clinically obvious.
There presently exists no efficient, reliable, non-invasive method for diagnosing visceral HSV infections in animals and humans.
It is an object of the present invention to provide a non-invasive method and composition for the rapid, efficient and reliable diagnosis of HSV infections in animals and humans.
SUMMARY OF THE INVENTION
The above and other objects are realized by the present invention which provides a method for the diagnosis of a HSV infection in a human or non-human patient in need thereof comprising intravenously administering to the patient a non-toxic amount of a non-invasively assayable ligand-labelled anti-viral drug; the drug comprising a compound which is phosphorylated by the HSV-induced thymidine kinase present in HSV-infected cells to the phosphorylated assayable ligand-labelled compound which is substantially non-diffusible from within the HSV-infected cells and non-invasively assaying the presence or absence of the accumulated phosphorylated assayable ligand-labelled compound in the cells.
An additional embodiment of the invention comprises a pharmaceutical composition in non-toxic, unit dosage, intravenously administrable form adapted for the diagnosis of a HSV infection in a human or non-human patient in need thereof comprising a non-invasively assayable ligand-labelled anti-viral drug comprising a compound which is phosphorylated by the HSV-induced thymidine kinase present in HSV-infected cells to a phosphorylated assayable ligand-labelled compound which is substantially non-diffusible from within the HSV-infected cells and a pharmaceutically acceptable carrier therefor.
DETAILED DESCRIPTION OF THE INVENTION
A number of anti-viral drugs exhibit marked accumulation in HSV infected cells in vitro. The virus induced enzyme thymidine kinase (TK) phosphorylates these drugs to the monophosphate, which is converted to the di and the triphosphate by cellular enzymes. This mechanism has been shown to lead to the intracellular accumulation of acyclovir [Furman et al, Antimicro. Agents Chemother., Vol. 20, pp. 518-524 (1981)], 9-(2-Hydroxyethyoxymethyl) guanine (DHPG) [Smee et al, Biochem. Pharmacol., Vol. 34, pp. 1049-1056 (1985)], trifluorothymidine (TFT) [Fischer et al, Mol. Pharmacol., Vol. 24, pp. 90-96 (1983), and others [Price et al, Human Herpesvirus Infections: Pathogenesis, Diagnosis and Treatment, In: Lopez et al (eds.) Raven Press, New York, N.Y., pp. 227-233 (1986)].
The literature contains contradictory data regarding HSV specific concentration of antiviral drugs in HSV infected tissues. Price et al Human Herpesvirus Infections: Pathogenesis, Diagnosis and Treatment. In: Lopez et al (eds.) Raven Press, New York, N.Y., pp. 227-233 (1986); Biochem. Pharmacol., Vol. 32, pp. 2455-61 (1983)] and Saito et al [Science, Vol. 217, pp. 1151-1153 (1982); Ann. Neurol. Vol. 15, pp, 548-558 (1984)] using 14 C labeled 2' fluoro-5-methyl-1-β-D-arabinosyluracil (FMAU) were able to show specific concentration of the drug in the optic nerve and chiasm of rats after intraocular inoculation of HSV-1. However, there is also non-specific accumulation of FMAU in the choroid plexus and the cells lining the ventricular walls. Biron et al [Antimicrob. Agents Chemother., Vol. 21, pp. 44-50 (1982)] studied 14 C labeled acyclovir, which has been shown to accumulate intracellularly in HSV infected cells in vitro [Furman et al, supra]. Following s.c. injection, acyclovir levels were similar in all HSV infected and uninfected tissues studied, i.e., liver, kidney, spleen, lung, blood and brain. Price et al were also unable to demonstrate any selective accumulation of acyclovir in HSV infected tissues in vivo [Price et al, supra]. It is difficult to reconcile the lack of accumulation of acyclovir in HSV infected tissues, with the observation herein of high levels of TFT in livers from HSV-2 infected mice, since both compounds are phosphorylated by the HSV TK and do accumulate in tissue culture.
Recently, Smee et al showed that while acyclovir accumulated in the form of phosphorylated intermediates in HSV infected cells, in vitro, it was also rapidly degraded back to acyclovir, and diffused out of the cell Smee et al, supra]. In contrast, DHPG also accumulated in a similar manner, but did not hydrolyze back to the parent compound as readily. Thus, even related drugs which utilize the some basic steps in their mechanism of action can behave quite differently biologically. Furthermore, i.v. injection of TFT via the jugular vein is used herein, which would result in extremely high blood levels initially, with a rapid fall off, as was observed, i.e., no detectable drug at 2 hours in the blood. When TFT was given by i.p. injection, it was impossible to demonstrate accumulation of TFT in the liver of HSV infected mice. Since Biron et al used s.c. injection, and since plasma levels remained reasonably elevated for 2 hours or more after injection, it is possible that the "depot" effect of s.c. injection, together with the propensity of phosphorylated acyclovir to be rapidly hydrolyzed back to the parent compound, was responsible for the lack of accumulation. Another difference between the present invention and the system of Biron et al is that herein drug levels were measured on day 2 or 3 after infection while their drug studies were carried out on days 4-5 after infection. It is very possible that the relationship between drug accumulation and level of infection changes during the course of the infection, and some preliminary observations in this regard are discussed below.
The present invention is predicated on the discovery that this phenomenon of accumulation of anti-viral drug metabolites in HSV-infected cells may be utilized to effectively and non-invasively diagnose HSV infections in humans and non-humans.
According to the present invention, a non-invasively or externally assayable ligand labelled derivative of the drug is intravenously administered to the patient and, following diffusion into and phosphorylation into non-diffusible derivatives and accumulation thereof in any HSV infected cells and then externally assayed to detect the presence or absence of the accumulation.
The ligand may be any conventional assayable ligand which does not render the drug or metabolite thereof toxic or unable to accumulate.
For example, TFT contains 3 fluorine atoms which comprise approximately 19% of its molecular weight. Since the naturally occurring isotope, 19 F has a nuclear spin of 1/2, sufficient concentrations of TFT can be detected by nuclear magnetic resonance spectroscopy. TFT concentrates in the tissues of HSV-2 infected animals thereby rendering the excess accumulation detectable, non-invasively, by 19 F NMR spectroscopy.
The method and composition of the invention are suitable for the diagnosis of HSV infection in human or non-human animals. The drug may be admixed with any suitable intravenously administrable carrier. Suitable carriers include physiologic saline, isotonic dextrose, isotonic buffers such as sodium hydrogen phosphate (NaH 2 PO 4 , Na 2 HPO 4 ) with ethyl alcohol, propylene glycol, benzyl alcohol, etc.
The drug is compounded with the carrier in unit dosage, i.v., administrable form in non-toxic amounts which will vary, depending upon the compound employed. It is only necessary to include an amount of compound in the composition which will accumulate in its metabolized form in the HSV-infected cells of the patient in amounts detectable by the assay procedure chosen. Again, the amounts will vary, depending upon the assayable ligand utilized and the particular assay method chosen.
The invention is illustrated by the following non-limiting examples:
EXAMPLE 1
Because TFT crosses the blood brain barrier poorly, TFT concentrations were measured in the livers of mice with hepatitis due to HSV-2 infection. For comparison, TFT levels were measured in the livers of uninfected mice and mice with carbon tetrachloride (CCl 4 ) induced hepatitis.
HSV-2 (333 strain) was grown and titered in Vero cells as previously described [Rand -t al, J. Med. Virol., Vol. 20, pp. 1-8 (1986).
The following strains of mice were obtained from the National Cancer Institute: Balb/c, CBA/J, A/HeN, A/J, P/N, and DBA/2N. Preliminary studies showed that the DBA/J strain consistently yielded the highest titers in the liver following intraperitoneal injection of the 333 strain of HSV-2. All further studies were therefore done with CBA/J mice, aged 4-6 weeks, weighing 18-23 g.
Carbon tetrachloride was dissolved in olive oil for injection. Trifluorothymidine was assayed by high pressure liquid chromatography (HPLC).
4-6 week old, 18-23 gm, CBA/J mice were injected intraperitoneally (i.p.) with 1.5 ml of HSV-2 (2-4×10 6 pfu/ml). In this model, maximal viral titers are present in the liver between days 3 and 5, and mice generally died from day 4 to 6 from this high inoculum. Three days after infection, mice were anesthetized with a 3:1 mixture of 100 mg/ml ketamine HCl:20 mg/ml Xylazine at a dose of 0.2 ml/kg. The jugular vein was surgically exposed, and mice were injected intravenously with 100 or 160 mg/kg of TFT in the appropriate volume of a 20 mg/ml solution in Phosphate Buffered Saline (PBS) pH 7.4. Mice were sacrificed at 45 minutes, 2 hours, 2.5 and 3.5 hours after I.V. injection of TFT. The livers were immediately excised and frozen at -70° C. until they could be studied. For viral titration and measurement of TFT, 1.5 ml of phosphate buffered saline pH 7.4 was mixed with 1 g of liver and the mixture homogenized (10 strokes using a Pyrex Ten Broeck tissue grinder), followed by sonication ×4 for 30 sec. in a Fisher 300 sonic dismembrator at a relative output of 0 55; 0.8 ml of the liver homogenate was mixed with an equal volume of methanol, vortexed extensively and then centrifuged at 15,000×g for 15 minutes. The supernatant was analyzed by HPLC for TFT and the results expressed per gram of liver after correction for dilution. Prior to sonication, 0.5 ml of the liver homogenate was serially diluted in serum free tissue culture media and titrated in triplicate in Vero cells as previously described [Rand et al, supra]. In some experiments the clarified supernatant that had been mixed with methanol as described above was placed in a 5 mm NMR tube and 19 F content measured by NMR spectroscopy. In other experiments the entire liver was excised, and placed in a 12 mm NMR tube and the 19 F directly analyzed by NMR spectroscopy.
Carbon tetrachloride was selected as a control for hepatitis because previous work suggested that the dose related hepatic toxicity was limited to the liver and did not involve the kidney which might conceivably alter the pharmacokinetics of TFT. CCl 4 induces a dose dependent patchy, centrilobular necrosis which is analogous to that induced by HSV infection of the liver. Prior to i.p. injection of CCl 4 in olive oil, 0.2 ml of blood was collected from each of a group of 5 mice. Twenty-four hours after i.p. injection of 0.1 ml/kg CCl 4 in olive oil, blood was collected again, and both sets were analyzed for Alanine Amino Transferase (ALT) and Blood Urea Nitrogen (BUN). For ALT, 2 μl serum was analyzed in duplicate with a Technicon RA 1000 and for BUN 10 μl duplicate samples were analyzed with a Beckman Astra 8. Mice were sacrificed by cervical dislocation and the liver and kidney fixed in 10% formalin, stained with hematoxylin and eosin and examined histologically.
19 F assay was carried out in a Nicolet-GE NT-300 NMR spectrometer, using standard techniques with a simple one-pulse sequence. The field was 7.05 Tesla (T) and the frequency was 282 megahertz. Depending upon the volume of the sample available, it was placed :n either a 5 mm or 12 mm diameter tube, which was usually not spun. Both whole liver and liver homogenates were placed in 2 ml of a 2:1 v/v mixture of D 2 O: methanol which inactivated HSV, permitted field homogeneity to be optimized and provided field-frequency lock for time averaging. A five-second cycle time was used with a tip angle of 60°. Sweep width was 5000 Hz and 64K data points were collected. Concentration of 19 F in a sample was evaluated by comparing the electronically integrated area of the resonance peak, after application of 10 Hz line broadening and Fourier transformation of the free induction delays using a 1280 computer, to that of standards containing 10, 50, or 100 μg/ml TFT Instrumental reproducibility of the calculated areas was checked by comparing the integral for the 40 μg/ml standard to that calculated from a scale setting obtained with a 100 μg/ml standard. In the calculation of TFT concentration, appropriate allowances were made for the dilution of the sample or for the size of the organ in the sample tube, as well as for the TFT extracted from the organ by the surrounding medium.
Because of the very wide variation in TFT levels and their relationship with viral titers above 10 6 pfu/g liver, it could not be assumed that TFT levels were normally distributed among HSV infected mice. Therefore, data were analyzed by the non-parametric Mann-Whitney U test.
Table 1 shows the results of a representative experiment in which TFT levels and viral titers were measured in the livers of HSV-2 infected and uninfected 4-6 week old CBA/J mice. Infected mice had a TFT mean ±SE of 110.1+52.7 μg/g liver, compared with 14.7+7.7 μg/g liver for uninfected mice, p=0.014, Mann-Whitney U.
CCl 4 was selected as a control for the effect of non-specific hepatic damage, because data in the literature suggested that it was essentially a pure hepatotoxin, with no effect on renal function. At a dose of 0.2 ml/kg in olive oil injected i.p., overwhelming hepatic necrosis results a day later, with ALT levels in blood typically in the range of 20,000-30,000 IU/ml (See Table 2). As shown by the BUN, there is no significant alternation in renal function. Histologically, there is a dose related centrilobular necrosis, which at 0.2 ml/kg is massive, but at 0.0 ml/kg is more localized and less extensive. Preliminary experiments were then carried out to determine the average ALT levels of HSV-2 infected mice on day 3 at the time higher levels of TFT were found in the liver. On day 3 following i.p. injection with 4-6×10 6 pfu HSV-2, 4 mice had an ALT mean ±SD of 3554±781 IU/ml blood. A dose response curve of CCl 4 hepatitis had shown that between 0.015-0.02 ml/kg CCl 4 would lead to ALT levels of 500-5000 IU/ml blood. Therefore, CCl 4 was used at a dose of 0.02 ml/kg.
FIG. 1 shows that there was essentially no difference in blood levels of TFT at 45 minutes after i.v. injection, and no measurable blood levels of TFT at 2 hours among any of the groups. HSV-2 infected mice had significantly higher levels of TFT in their livers at both 2 and 3.5 hours after i.v. injection of TFT, whether compared with uninfected or CCl 4 treated mice.
If TFT levels in liver were due to accumulation in HSV infected liver cells, then the higher the HSV titer/g liver, the higher the TFT level should be. The relationship between HSV-2 pfu/g liver and TFT concentration/g liver among infected mice is illustrated in 2 separate experiments in FIG. 2. Linear regression showed a correlation coefficient of r=0.72, p<0.05 in one experiment (O's) and r=0.99, p<0.05 in the second ( 's). A similar relationship was also observed among infected mice studied at 3.5 h after receiving TFT as well as those receiving the higher dose of 160 mg/kg TFT shown in Table 1.
Sufficient material was available from 4 mice/group to measure 19 F levels by NMR spectroscopy of the whole liver under conditions as described. The results are shown in Table 3 compared with the HSV pfu/g liver where applicable and the TFT levels as measured on a small portion of same samples by HPLC. By linear regression, the correlation between HPLC and NMR was r=0.91, p<0.0005.
FIG. 3 shows actual 19 F NMR tracings of A) the 40 μg/ml standard, B) liver homogenate from an HSV-2 infected mouse 3.5 hours after i.v. injection of 100 mg/kg TFT; the area under the peak corresponds to 11 μg/g liver C) liver homogenate from a CCl 4 treated mouse 3.5 hours after i.v. injection of 100 mg/kg TFT and D) liver homogenate from an uninfected mouse 3.5 hours after i.v. injection of 100 mg/kg TFT.
As a further specificity control 10 CBA mice were infected with murine hepatitis virus (MHV-A59), a coronavirus which does not contain thymidine kinase. As shown in FIG. 4, there was no increased concentration of TFT in livers of 10 MHV infected mice 2 h after i.v. injection of TFT, compared with the levels found in uninfected mice in the same experiment. In contrast, the 2 HSV-2 infected mice with titers of 10 6 pfu HSV/g liver, had strikingly elevated levels.
Significantly higher levels of TFT were observed in the livers of HSV-2 infected mice, as compared with those of either uninfected mice or mice treated with CCl 4 . The effect was repeatedly demonstrated, and correlated with the level of HSV-2 infection. Since blood levels among HSV-2 infected mice were similar to or even lower than those of uninfected mice or CCl 4 treated mice, it seems unlikely that delayed excretion or otherwise altered pharmacokinetics could account for the higher levels of TFT observed in the HSV-2 infected livers. Non-specific accumulation due to hepatic damage seems unlikely as well in view of the results in CCl 4 hepatitis.
Nuclear magnetic resonance spectroscopy was used herein to measure levels of 19 F. Since there is essentially no tissue background level of fluorine, the area under the curve is directly related to a standard and is used to estimate tissue levels of TFT. TFT levels in the range of 50-100 μg/g tissue were readily detected, and even at the 1:6 dilution used, required only 10 min acquisition time, albeit at a high field strength of 7.05 T. Although the highest field strengths used diagnostically in humans are about 2 T, 19 F NMR surface coil technology has sufficient sensitivity in this range of field strength. For example, a Biospec system operating at 94 MHz was used to investigate metabolites of 5-fluorouracil (5 FU), and had a detection limit of 0.1 μmol/g in a mouse liver and a mouse tumor with 10-20 min acquisition times (manufacturer's technical information). Wolf et al reported similar studies of the behavior of 5 FU in human liver, obtaining suitable spectra in 8 min in a field of 1.5 T [Wolf et al, In: Abstracts of the Society of Magnetic Resonance in Medicine, 5th Annual Meeting, Montreal, 1986.].
One interesting finding was that the higher levels of TFT could be found in the livers of HSV-2 infected mice on day 2 as well as day 3 following HSV-2 infection. Here, the viral titers were quite low (10 3 /g liver) compared with those in mice demonstrating the TFT accumulation on day 3, (≧10 6 pfu/g liver). ALT levels in blood in mice 2 days after HSV infection were also much lower, compared with day 3, and were in the range of 500 IU/ml blood; but data was only available from a small number of animals. Since the HSV induced TK is maximally produced approximately between 7-15 hours after infection [Kit et al, Symp. Quant. Biol., Vol. 39, pp. 703-715 (1975); Fong et al, J. Virol. Vol. 34, pp. 644-649 (1980)] which is before release of infectious virus, it is possible that early in the course of infection in vivo, as virus is spreading rapidly and infecting ever increasing numbers of new cells, higher levels of TK are present relative to the number of infectious virions, resulting in greater uptake of TFT per infectious unit.
In summary, highly elevated levels of TFT were observed in livers of HSV-2 infected mice compared with either uninfected or CCl 4 treated mice. There was good correlation between TFT levels in liver tissue and HSV-2 titers in the same tissues. Neither altered pharmacokinetics, nor non-specific liver damage could account for the observed drug accumulation. NMR spectroscopy has the sensitivity to detect high levels of TFT readily, and thus offers a potentially non-invasive method for the diagnosis of visceral HSV infection.
TABLE 1______________________________________TFT concentration in livers of mice infected with160 mg/kg TFT I.V. and sacrificed at 2 hours.INFECTED UNINFECTEDViral titer Conc. of TFT Conc. of TFT(PFU/g liver) (μg/g liver) (μg/g liver)______________________________________1.1 × 10.sup.7 266.6 36.52.4 × 10.sup.6 60.2 2.51.1 × 10.sup.6 74.6 14.33.4 × 10.sup.3 38.9 5.6Mean* 110.1 14.7______________________________________ *p = 0.014 Infected vs. Uninfected, Mann Whitney U, see Methods for explanation.
TABLE 2______________________________________Blood levels of Blood Urea Nitrogen and SerumAlanine Aminotransferase levels in CarbonTetrachloride and Herpes Simplex Virus-2treated CBA/mice Mean ± SD BUN* ALT.sup.+Treatment mg/dl IU/L______________________________________CCl.sub.4Pre treatment (N = 5).sup. 10.4 + 2.7 28.2 ± 13.824 h post treatment 6.4 ± 2.3 28112 ± 6086(N = 5).sup.24 h post treatment .sup. ND.sup.11 18950 ± 7526(N = 12).sup.§7526HSV-248 h post infection ND 50072 h post infection ND 3554 ± 781(N = 4)______________________________________ *10 μl serum, BUN measured with the Beckman Astra 8 .sup.+ 2 μl serum, ALT measured with the Technicon RA 1000 .sup. Mean ± SD of the BUN and ALT prior to CCl.sub.4 treatment and from the same mice 24 hours later, CCl.sub.4 used at 0.2 ml/kg i.p. .sup.§ Mean ± SD of the 12 CCl.sub.4 treated mice shown in FIG. 1 45 minutes (N = 4) 2 h (N = 4) and 31/2 h (N = 4) after receiving 100 mg/kg TFT, CCl.sub.4 used at 0.02 ml/kg. .sup.11 ND = Not Done
TABLE 3______________________________________TFT concentration (μg/g liver) measured by HPLCand .sup.19 F NMR 2 hours after intrajugular injectionof 100 mg/kg TFT in CBA/J miceTFT μg/g Liver Viral Titer* HPLC.sup.+ NMR.sup.______________________________________HSV-2 Infected#1 7.5 × 10.sup.6 152.1 90#2 6.6 × 10.sup.6 149.1 182.5#3 6.1 × 10.sup.6 38.9 25#4 3.6 × 10.sup.6 63.6 55Uninfected#1 N/A 16.0 45#2 N/A 3.5 0#3 N/A 13.8 20#4 N/A 9.9 tr§CCl.sub.4 Hepatitis#1 N/A <1.0 tr#2 N/A <1.0 tr#3 N/A <1.0 0#4 N/A <1.0 0______________________________________ *pfu/g Liver .sup.+ Correlation coefficient, HPLC vs. NMR r = 0.91, p < 0.0005. .sup. Calculated from the area under peak at -63 ppm (relative to CFCl.sub.3) § = trace.
DETAILED DESCRIPTION OF THE DRAWINGS
FIGS. 1-3 are graphic depictions of the results of Example 1.
In FIG. 1, 1 HSV-2 infected, uninfected and CCl 4 treated 4-6 week old CBA/J mice were injected via the jugular vein with 100 mg/kg TFT, and sacrificed at 45 minutes, 2 hours or 3.5 hours later. The figure shows the mean ±SE of the TFT concentration in blood or liver measured by HPLC as described in the methods. Most of the experiments were done on day 3 after HSV infection; day 2 after infection was not systematically studied, and is presented only for comparison.
In FIG. 2, the relationship between HSV-2 titer/g liver and TFT concentration/g liver measured by HPLC on day 3 after HSV-2 infection, 2 h (O's) and 2.5 h ( 's) following i.v. administration of TFT. Two separate experiments are shown. Data were analyzed by linear regression. For comparison, TFT levels in the livers of the 9 uninfected mice used in these two experiments were pooled and the mean ±SD shown.
In FIG. 3, representative 19 F NMR spectra was measured with the Nicolet GE NT-300 NMR spectrometer at a field strength of 7.05 T, using a 2:1 v/v D 2 O/methanol mixture as a field-frequency lock. A) 40 μg/ml TFT standard, acquisition time≈7 min. B) HSV-2 infected mouse, day, 3 3.5 h after i.v. administration of 100 mg/kg. Liver homogenate prepared as described in the methods. Acquisition time was ≈28 min, and TFT concentration was 11 μg/g liver by NMR C) CCl 4 treated mouse, 3.5 h after i.v. administration of 100 mg/kg TFT, liver homogenate, prepared as described in the methods. Acquisition time was 1.9 hours, which accounts for the low noise level. D) uninfected mouse 3.5 h after i.v. administration of 100 mg/kg TFT, liver homogenate prepared as in the methods. Acquisition time ≈28 min. Horizontal line in B represents the cumulative area under the curve.
According to the results depicted in FIG. 4, infection of CBA/J mice with MHV-A 59 showing levels of TFT in the same range as that of uninfected mice. No relationship between MHV titer and TFT level was observed. As a positive control, other CBA/J mice were infected with HSV-2 at the same time as those infected with MHV-A 59 and those infected with HSV-2 in the range of 10 6 pfu/g liver again showed high levels of TFT in liver. Symbols used: =HSV-2; O=MHV-A 59; Δ=uninfected. | 4y
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BACKGROUND OF THE INVENTION
This invention relates generally to circular knit, tubular one-piece blanks and garments formed therefrom, such as briefs and panties, and to the method of forming the blanks and garments. More particularly, the invention relates to a knitted, seamless, tubular blank having a two ply crotch section and the forming of a body garment.
Heretofore, undergarments such as panties and briefs have generally been made from a plurality of component parts configured to the desired shapes and then sewn together. Such garments made by the "cut and sew" methods are expensive to manufacture due to the labor costs involved in accurately cutting and seaming the components and due to the waste of materials.
Efforts have been made to reduce labor and fabric waste by knitting a plurality of blanks as disclosed, for example, in U.S. Pat. No. 4,663,946. The side-by-side knit blanks are in the form of a tube which is slit walewise to form two blanks. Each blank is then folded and sewn resulting in seams along both sides of the garment. U.S. Pat. No. 4,624,115 discloses a seamless knit tubular blank wherein the blank is provided with visual cutting guides formed during the knitting operation, which serve to facilitate an operator in removing fabric portions from the blank to impart the requisite shape for forming the garment therefrom. As disclosed in U.S. Pat. No. 4,043,156, an undergarment is made from a rotary knitted blank having a body section and discreet depending panels. Knitting is continued upon spaced groups of needles. Portions of the panels are overlapped and sewn together to shape the blank into a garment. In each of U.S. Pat. Nos. 4,043,156 and 4,624,115 the portion of the garment is formed by sewing together depending front and rear panels of the blanks.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
In accordance with this invention, a circular knitting machine knits a given number of courses in the forming of a body portion of a panty or brief. Interknitted integrally with the body portion is a two ply crotch section of a desired width formed in the manner of a knitted or turned welt.
Initially, a turned welt is formed on a knitting machine as disclosed, for example, in U.S. Pat. Nos. 2,730,880; 2,785,552; and the like. Knitting machines for producing a loop in the fabric in the form of a turned welt are widely used in the industry and their construction and mode of operation are well known. The main body section of the blank is then knit followed by the knitting of the crotch section. The width of the crotch section may vary, as desired. In a preferred embodiment, the crotch section extends around approximately 25% of the body section. The crotch section is formed by knitting partial courses using the machine cylinder needles and dial bits in the manner of forming the loop portion of a knitted welt, with the length of the double ply crotch section being variable depending upon the desired size, style, etc. of the garment. The amount of fabric forming the body section may also be varied depending upon size and style of the garment. The crotch section and the body section may then be cut to the desired size and shape or contour prior to sewing the crotch section to the back of the body section.
One of the primary objects of the invention is the provision of a simplified and improved unitary brief or panty type garment having a two ply crotch section interknitted with the garment body section.
Another object of the invention is the provision of a one-piece brief or panty having no seams at the juncture of the body with the two ply crotch resulting in a garment of improved appearance.
Still another object of the invention is the provision of an improved method of forming the garment in a novel manner upon a circular knitting machine resulting in a simplified and improved garment structure.
A further object of the invention is the provision of a one-piece brief or panty type garment having a two ply crotch which may economically knit on a circular knitting machine. In order to make the body section more nearly conform to the shape of the body of the wearer during the knitting process and to save material, certain portions of the body section may be knit of partial courses.
Other objects and advantages of the invention will become apparent when considered in connection with the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a perspective view of a blank of this invention formed by a circular knitting machine;
FIG. 2 illustrates the blank of FIG. 1, rotated about the vertical axis approximately 180°, and having fabric cut and removed to define leg openings;
FIG. 3 is a front view of the blank having the crotch section cut to the desired contour and having suitable trimming sewn in place around the leg openings;
FIG. 4 is a front view of a knitted one-piece garment of the present invention;
FIG. 5 is a perspective view of the garment of FIG. 4;
FIG. 6 is a front view of a garment blank formed in accordance with the present invention which has been turned inside out and illustrating guide lines in the crotch section;
FIG. 7 is a perspective view of a modified embodiment of a garment blank of this invention;
FIG. 8 is a perspective view of another embodiment of a garment blank of the present invention; and
FIG. 9 is a fragmentary transverse sectional view of a knitting machine, needles, needle cylinder, dial and dial bits, and illustrating the formation of the crotch section.
DESCRIPTION OF THE INVENTION
As illustrated in FIG. 1, a unitary, seamless knit, tubular garment blank 10 of the present invention includes a waistband 12, a plurality of 360° courses forming a lower trunk engaging body section 14, and a crotch section 16 integrally knit with and extending from the body section 14.
The waistband 12 may be in the form of a transfer or double welt and may include elastic material. The fabric which forms the turned welt is knit on cylinder needles and dial bits in a well known manner. This is followed by the knitting of the tubular body section 14 down to a given course 20 where a majority of the needles discontinue knitting (pressed off) and remaining needles extending around approximately 25% of the cylinder continue to knit so as to form the crotch section 16.
Throughout the specification and claims the terms "upper", "lower", "side", "front" and "back" used in referring to the garment and garment blank are based on the garment as worn on the body.
The length and diameter of the body section 14 may be varied, as desired, to provide the particular desired shape or contour, size and style of the finished garment. The body fabric may be of one or more suitable yarns and stitch constructions.
Preferably guide lines 22 are provided on each side portion 24, 26 of the body section for serving as cutting guides for removing fabric to define leg openings. The guide lines 22 may be formed during the knitting process in any suitable manner e.g., by tuck stitches as disclosed, for example, in U.S. Pat. No. 4,624,115.
At the last course 20, needles around approximately 75% of the knitting circle are pressed off while the remaining needles and dial jacks cooperate in a conventional manner, as in the construction of a turned welt to form the double ply crotch section 16. The fabric of the crotch section extends around approximately 25% of the knitting circle and has portions held by hooks 28 on the dial jacks 30, FIG. 9, while knitting continues on selected needles 33. The length of the fabric F for forming the plies of the crotch section 16 may vary in length. After a predetermined amount of fabric F is made, the yarn held by the hooks 28 is transferred to selected needles 33 and looped together as shown by numeral 35, FIG. 2, to interlock the two plies of the crotch section adjacent the course 20. The inner and outer plies 36, 38 may be of the same or different yarns and yarn constructions.
The body section 14 of the blank 10 of FIG. 1 may then be severed along or adjacent guide lines 22, 22 on the sides and front of the blank to define leg openings, and the crotch section 16 may be cut to the desired contour, as shown by FIG. 3. Suitable trimmings 34 may then be sewn along the severed edges of the crotch and body sections as shown by FIG. 3. The free end portion 40 of the shaped double ply crotch is sewn to lowermost edge portions of the back portions 37 of the body section by stitching 39 resulting in a garment as shown by FIGS. 4 and 5.
FIG. 6 illustrates a garment blank according to the present invention which has been turned inside out and illustrating the crotch being knit of two different interknit fabric constructions 44, 46. The juncture 48 of the two fabric constructions serves as a guide line for assisting in cutting the crotch section 16 to the desired contour.
FIG. 7 illustrates another embodiment of a unitary tubular knit garment blank according to the invention wherein, in order to save material, the body section 14 is knit down to a given course 50 and selected needles are pressed off and other selected needles continue to knit a rear or back panel 52. The sides 24, 26 and rear panel 52, and crotch 16 are severed to the desired contour to define leg openings.
FIG. 8 illustrates another embodiment of the invention wherein the body section 14 is knit in a particular manner on the sides 24, 26 to save raw material and require less cutting in defining leg openings. The leg openings may be formed as disclosed in U.S. Pat. No. 4,010,627 with the edges having short fringe-like lengths of yarn 60. The crotch section inner ply 38 may be of cotton yarn. The yarns and yarn constructions of the inner and outer plies may vary as required. The change from one type of yarn to another may be made at any time during the knitting of the fabric loop F which forms the two plies.
It will be understood that the details of construction and procedure of the invention set forth herein are merely by way of example and the invention is to be limited only by the scope of the appended claims. | 4y
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BACKGROUND OF THE INVENTION
[0001] Files and file operations, such as read, write, open, close, and the like are familiar with computer users and programmers. Because of this familiarity, the file system paradigm has been employed to monitor and manage other processes and entities, which may not, at first glance, be thought of as data storage files.
[0002] For example, one of the main functions of an operating system is to manage tasks or processes executed in a computer system. If the data pertaining to the tasks or processes can be represented as files, these tasks or processes can be monitored and/or manipulated and/or controlled using the familiar file system commands. In UNIX, for example, there is provided a process file system or ProcFS to manage the interactions between the applications and the tasks/processes, which have been modeled by files in order to allow the applications to monitor and/or control the tasks/processes using the familiar file system user command and application program interface.
[0003] To facilitate discussion, FIG. 1 illustrates a typical ProcFS arrangement in which a ProcFS 102 is employed to facilitate the interactions between applications 104 and a plurality of kernel subsystems 106 , 108 , 110 and 112 . Within each kernel subsystem, there is provided one or more internal kernel data structures, which reflect the status of the associated kernel subsystem and contain information that ProcFS 102 wishes to monitor and/or control. These internal kernel data structures are shown for kernel subsystems 106 , 108 , 110 and 112 as respective internal kernel data structures 114 , 116 , 118 and 120 .
[0004] In the example of FIG. 1, kernel subsystem 106 represents a file descriptor subsystem, which deals with the set of open files for processes in the system. Kernel subsystem 108 represents the scheduler subsystem, which schedules execution entities in the system. Kernel subsystem 110 represents the task/process subsystem, which manages the creation and destruction of threads, processes, and tasks in the system. Kernel subsystem 112 represents the virtual memory subsystem, which manages virtual and/or real memory for the processes. ProcFS 102 and the various kernel subsystems may reside in the operating system's kernel space. Unlike other file systems, the end user cannot add, delete, and modify files in ProcFS.
[0005] ProcFS 102 includes a plurality of pseudo-files whose contents are created based on the internal kernel data structures of their respective kernel subsystems. That is, a pseudo-file that is associated with a kernel subsystem reflects the data in the internal data kernel structure of its associated kernel subsystem. If the data within internal kernel data structure 114 of kernel subsystem 106 changes, for example, the content of pseudo-file 130 , which is associated with kernel subsystem 106 , would correspondingly change.
[0006] When an application makes a call into ProcFS 102 to request monitoring and/or controlling one of the kernel subsystems, ProcFS 102 opens the pseudo-file(s) the application is interested in and allows the application to access the contents of the appropriate pseudo-file(s) in order to monitor the operation of the associated task/process in the relevant kernel subsystem and/or to control its operation by writing parameters, for example.
[0007] Although the ProcFS arrangement of FIG. 1 (and its variations) has been in use for some time, there are disadvantages. One of the main disadvantages of the ProcFS arrangement of FIG. 1 relates to the monolithic nature of ProcFS 102 . In ProcFS 102 , the set of pseudo-files (e.g., pseudo-files 130 , 132 , 134 and 136 ) as well as the content, format, and file directory hierarchy of each, is determined by the OS engineers at the time of OS creation and is fixed at the time of OS creation. If one of the kernel subsystems is modified, or a new kernel subsystem is desired, ProcFS 102 must be modified as a single unit.
[0008] Because there is no industry standard that governs the content, file format, and file directory hierarchy of ProcFS 102 , different vendors implement ProcFS 102 differently, and even the same vendor may implement ProcFS 102 differently from version to version. Thus, when a user wishes to make changes to one of the kernel subsystems or wishes to introduce a new kernel subsystem, the OS engineers who originally designed ProcFS 102 may need to be consulted. Because of the complex nature of operating systems and its various subsystems, it is generally the case that different teams within the company that supplies the OS may need to coordinate in order to change ProcFS 102 .
[0009] This situation is conceptually illustrated in exemplary FIG. 2, wherein ProcFS team 202 must coordinate with file system team 204 , process management team 208 , virtual memory team 210 , as well as with individuals outside of OS company 212 (such as one or more independent software vendors, ISV 214 ) in order to create an updated or a new ProcFS 216 . The complexity involved in making a change to the prior art ProcFS often results in an undue amount of delay in delivering the updated ProcFS to the customer requesting the change, thus giving rise to customer dissatisfaction.
[0010] Furthermore, when application 104 of FIG. 1 makes a call into ProcFS 102 , the resultant query into pseudo-file 130 crosses subsystem boundaries. This is an undesirable data coupling behavior from a modularity point of view, which behavior is a direct result of the monolithic nature of ProcFS 102 . The data coupling makes maintenance and update of ProcFS 102 unnecessarily complex as well reducing its overall reliability.
SUMMARY OF THE INVENTION
[0011] The invention relates, in one embodiment, to a process file system in an operating system of a computer, the process file system being configured to allow an application program to monitor information pertaining to a plurality of subsystems. The process file system includes a virtual process file system layer for interacting with the plurality of subsystems in a substantially content-independent manner. The process file system also includes a plurality of content-dependent modules, each of the plurality of subsystems being associated with at least one of the plurality of content-dependent modules, a first content-dependent module of the plurality of content-dependent modules being configured to access a first data structure of a first subsystem of the plurality of subsystems. The process file system additionally includes an interface facilitating data exchange between the plurality of content-dependent modules and the virtual process file system layer. The process file system further includes a directory structure table, the directory structure table containing names of the plurality of content-dependent modules, a name of the plurality of content-dependent modules being registered with the directory structure table by respective one of the plurality of content-dependent modules upon initialization of the respective one of the plurality of content-dependent modules, wherein at least one name associated one content-dependent module of the plurality of dependent modules is registered in the directory structure table as a dynamic name.
[0012] In another embodiment, the invention relates to a method for facilitating interaction between an application program and a plurality of subsystems. The method includes providing a virtual process file system layer, the virtual process file system layer being configured to interact with the plurality of subsystems in a substantially content-independent manner. The method further includes providing a plurality of content-dependent modules, each of the plurality of subsystems being configured to be associated with at least one of the plurality of content-dependent modules, a first content-dependent module of the plurality of content-dependent modules being configured to access a first data structure of a first subsystem of the plurality of subsystems. The method additionally includes providing an interface for facilitating data exchange between the plurality of content-dependent modules and the virtual process file system layer. The method further includes providing a directory structure table, the directory structure table being configured to track names of the plurality of content-dependent modules, a name of the plurality of content-dependent modules being configured to be registered with the directory structure table by respective one of the plurality of content-dependent modules upon initialization of the respective one of the plurality of content-dependent modules, wherein at least one name associated one content-dependent module of the plurality of dependent modules is configured to be registered in the directory structure table as a dynamic name.
[0013] In yet another embodiment, the invention relates to a method in a computer for facilitating interaction between an application program and a subsystem. The method includes providing a virtual process file system layer. The virtual process file system layer is configured to interact with the subsystem in a substantially content-independent manner. The method additionally includes providing a content dependent module, the content dependent module being associated with the subsystem and is configured interact with the subsystem in a content-dependent manner. The method further includes providing a directory structure table, the directory structure table being configured to track a name of the content dependent module, wherein the content-dependent module is configured to be registered with the directory structure table using a dynamic name.
[0014] These and other features of the present invention will be described in more detail below in the detailed description of the invention and in conjunction with the following figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
[0016] [0016]FIG. 1 illustrates a typical ProcFS arrangement in which a ProcFS is employed to facilitate the interactions between the applications and a plurality of kernel subsystems.
[0017] [0017]FIG. 2 conceptually illustrates the coordination effort required to update a prior art ProcFS.
[0018] [0018]FIG. 3 shows, in accordance with one embodiment of the present invention, a simplified architecture diagram of the ProcFS system in which the ProcFS has been partitioned into a virtual ProcFS layer and a content-dependent layer.
[0019] [0019]FIG. 4 shows in greater detail, in accordance with one embodiment of the present invention, a ProcFS arrangement in which the ProcFS has been partitioned into a virtual ProcFS layer and a content-dependent layer.
[0020] [0020]FIG. 5 a shows, in accordance with one embodiment of the present invention, a virtual ProcFS layer view of an exemplary directory structure as registered by the content-dependent modules.
[0021] [0021]FIG. 5 b shows, in accordance with one embodiment of the present invention, the application view of the exemplary directory structure of FIG. 5A.
[0022] [0022]FIG. 6 conceptually illustrates, in accordance with one embodiment of the present invention, the ability of the inventive procFS to allow individual content-dependent modules to be dynamically loaded during an update cycle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The present invention will now be described in detail with reference to a few preferred embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps and/or structures have not been described in detail in order to not unnecessarily obscure the present invention.
[0024] In accordance with one embodiment of the present invention, the ProcFS is partitioned into two distinct layers: a virtual ProcFS layer and a content-dependent layer. The virtual ProcFS layer is responsible for interacting with the applications in a substantially content-independent manner, i.e., in a manner that it is substantially independent of the content, format, and file directory hierarchy of the files that reflect the internal kernel data structures within the various kernel subsystems.
[0025] The content-dependent layer contains a plurality of content-dependent modules. Each content-dependent module includes the file(s) which reflect the data in the internal kernel data structure of its associated kernel subsystem, as well as any necessary logic to access the internal kernel data structure to reflect the aforementioned data in the file(s). By performing file system-like operations on these files, the applications can monitor and/or control the operation of the kernel subsystems using the familiar file system paradigm.
[0026] Between the virtual ProcFS layer and the plurality of content-dependent modules in the content-dependent layer, there is provided a well-defined interface to allow any content-dependent module to register with the virtual ProcFS layer and to communicate therewith. Except through the interface, there is no direct data coupling between the virtual ProcFS layer and the plurality of content-dependent modules.
[0027] When a new content-dependent module is loaded into the system, the content-dependent module informs the virtual ProcFS layer of its name and its location to allow the virtual ProcFS layer to subsequently access the content-dependent module, and more specifically the content of the file(s) therein, in order to monitor and/or update the contents of the internal kernel data structures in the kernel subsystem of interest.
[0028] In this manner, when a kernel subsystem needs to be updated or a new kernel subsystem needs to be introduced, its associated content-dependent module can be loaded into the system, registered with the virtual ProcFS layer, and the associated content-dependent module can begin to provide information pertaining to its associated internal kernel data structure to the requesting application without requiring changes to other parts of the ProcFS.
[0029] Furthermore, there is provided, in accordance with one embodiment of the present invention, a technique for allowing a content-dependent module to register itself even though its exact name as required by the calling application may be unknown until the time the content-dependent module is called by the application. In one embodiment, simple enumerations in the user/application view are represented in the virtual ProcFS layer view in accordance with an inventive naming convention for representing dynamic names. Dynamic names registered at registration time are then dynamically generated into name instances when the modules are called by the applications.
[0030] By allowing content-dependent modules to register themselves using dynamic names, there is advantageously no need to know in advance at registration time the file directory hierarchy and/or the exact names required by the application at execution time. This is important for transient tasks and processes that may come and go, and facilitates plug-and-play replacement and/or addition of content-dependent modules.
[0031] The features and advantages of the present invention may be better understood with reference to the drawings and discussions that follow. FIG. 3 shows, in accordance with one embodiment of the present invention, a simplified architecture diagram of the ProcFS system in which the ProcFS has been partitioned into a virtual ProcFS layer and a content-dependent layer. User-application 302 accesses ProcFS 304 via a virtual file system 306 . A line 312 delineates the user space, which is above line 312 , from the kernel space of the operating system, which is drawn below line 312 .
[0032] Virtual file system 306 supports multiple individual file systems and contains the abstractions of the individual file systems so that the applications can make high-level calls (such as read, write, seek, open, load, and the like) without having to know the specifics of the individual file systems. Exemplary file systems shown in FIG. 3 include ProcFS 304 , NFS (Network File System) 308 , NTFS (Windows NT File System) 310 , and the like. Thus, ProcFS is seen as another file system from the perspective of the applications.
[0033] ProcFS 304 itself is further partitioned into a virtual ProcFS layer 320 and a content-dependent layer containing a plurality of content-dependent modules 322 , 324 and 326 . A common interface 328 allows any content-dependent module to load itself into ProcFS 304 , to register itself with virtual ProcFS layer 320 , and to render the contents of its file(s) accessible to application 302 in a substantially content-independent manner.
[0034] [0034]FIG. 4 shows in greater detail, in accordance with one embodiment of the present invention, a ProcFS arrangement in which the ProcFS has been partitioned into a virtual ProcFS layer and a content-dependent layer. In FIG. 4, application 402 accesses the ProcFS through a virtual file system 404 . Virtual ProcFS layer 406 of the ProcFS receives a request from application 402 via virtual file system 404 , which request may pertain to, for example, a request to monitor data within internal kernel data structures associated with kernel subsystems 410 , 412 , 414 or 416 .
[0035] In the example of FIG. 4, kernel subsystem 410 represents the file descriptor subsystem; kernel subsystem 412 represents the scheduler subsystem; kernel subsystem 414 represents the task/process subsystem; and kernel subsystem 416 represents the virtual memory subsystem. Within each kernel subsystem of FIG. 4, there is shown an internal kernel data structure. Internal kernel data structures 420 , 422 , 424 and 426 correspond to respective kernel subsystems 410 , 412 , 414 and 416 of FIG. 4.
[0036] After receiving the request from application 402 , virtual ProcFS layer 406 consults a directory structure table 430 to ascertain the name of the content-dependent module responsible for providing the requested data. The name of the responsible content-dependent module is typically derived from the parameters given by application 402 . The lookup provides the name of the responsible content-dependent module, which is then employed by virtual ProcFS layer 406 to access the file or files associated with the content-dependent module. As mentioned, the contents of the file or files provided in the content-dependent module reflect(s) the data in the internal kernel data structure within the kernel subsystem of interest to the calling application.
[0037] For example, if a lookup reveals that application 402 wishes to access information pertaining to kernel subsystem 410 , virtual ProcFS layer 406 would look up the name of content-dependent module 440 associated with kernel subsystem 410 and employs the content-dependent module 440 to provide the data contents of the file to allow application 402 to monitor the data in internal data kernel data structure 420 of kernel subsystem 410 .
[0038] The details required to access internal kernel data structure 420 are encapsulated within content-dependent module 440 . That is, virtual ProcFS layer 406 is not required to know the details regarding the content and format of internal kernel data structure 420 to service the request by application 402 . Furthermore, virtual ProcFS layer 406 does not need to know the exact directory hierarchy required for calling content-dependent module 440 since this information is encapsulated in directory structure table 430 . Directory structure table 430 itself is maintained by the content-dependent modules and support module 462 . A similar arrangement exists with respect to kernel subsystems 412 and 416 in that each is associated with a content-dependent module ( 442 and 452 respectively).
[0039] There is shown associated with kernel subsystem 414 a plurality of content-dependent modules 444 , 446 , 448 and 450 . Multiple content-dependent modules can be provided for a given kernel subsystem to provide different information to the virtual ProcFS layer. As shown in FIG. 4, the communication between virtual ProcFS layer 406 , the various content-dependent modules, and support function 462 is accomplished via a common interface 460 . Any content-dependent module written to conform to common interface 460 may be dynamically loaded into and removed from the ProcFS arrangement of FIG. 4 without requiring changes to other parts of the ProcFS system.
[0040] [0040]FIG. 4 also shows a support module 462 . One of the main functions of support module 462 is to provide for the registration of content-dependent modules into directory structure table 430 , and the removal of the entries from directory structure table 430 when a given content-dependent module is unloaded. When the module is first initialized, either at system initialization or when the content-dependent module is dynamically loaded, the content-dependent module calls support module 462 to register itself with directory structure table 430 . Among the information provided to directory structure table 430 are the name of the content-dependent module and the memory address of the content-dependent module so that the content-dependent module can be called upon by the virtual ProcFS layer 406 when virtual ProcFS layer 406 consults directory structure table 430 in response to a request by application 402 . Support module 462 also performs other housekeeping functions, such as memory management, buffer management, tracking the content of the register states, and the like.
[0041] Because virtual ProcFS layer 406 is not required to know the details regarding the content or format of the internal kernel data structure within the kernel subsystems, and in fact is not required to know the exact directory hierarchy in directory structure table 430 , there is no need to change virtual ProcFS layer 406 when a kernel subsystem is updated or a new kernel subsystem is loaded. As long as the content-dependent module (which encapsulates the details necessary to access the internal kernel data structure of the kernel subsystem of interest) conforms to common interface 460 , neither virtual ProcFS layer 406 nor other content-dependent modules of the ProcFS system needs to be modified.
[0042] Since the processes or tasks are modeled as files, access to the content-dependent modules follows the file system paradigm and uses a combination of the directory hierarchy path name and file name in order to accomplish the file system-like calls. There are at least two types of entries in the process file system, static and dynamic. Generally speaking, static entries are employed in those cases where the actual names are known at the time of registration. A static entry does not change until the entry is deleted. The static name shown by reference number 442 in FIG. 4 is one such example.
[0043] Dynamic entries are those which come into existence when the application/user requests for them. Examples include representation of processes as directories that are named after process id's, representation of threads that are named after thread id's, and the like. Processes and threads are transient that come and go. Accordingly, it is not possible to know in advance at registration time the number and names of processes or threads within a process in the system since they may change from one point in time to the next. To render the virtual ProceFS layer (such as virtual ProcFS layer 406 of FIG. 4) truly virtual and independent of the file organization associated with the content-dependent layer, it is important to be able to accommodate both static and dynamic entries.
[0044] In the prior art monolithic model, there was no concept of separate content-independent and content dependent layers. The content/format and directory structure knowledge was built into the monolithic implementation. Even for prior art implementations that support limited plug-ins, such as in the Linux case, the plug-in modules only support static entries and do not support dynamic entries.
[0045] In accordance with one aspect of the present invention, an inventive technique is employed to allow a content-dependent module, whose exact name may not be known at the time of registration, to register itself with the directory structure table. One embodiment facilitates the creation of simple enumerations, which are then dynamically generated into name instances when the registered content-dependent modules are called by the application. The technique may use special naming conventions distinct from names used for static entries. In the examples that follow, the hash symbol (#) is employed although other unique symbol or combination of symbols may well be employed.
[0046] In the exemplary directory structure table 430 , the hash (#) symbol is shown in the module names registered in boxes 469 a , 470 a , 472 a , 474 a , 476 a , 478 a and 482 a to denote that these are dynamic names. These names correspond to the content-dependent modules supporting the corresponding subsystems shown in column B of directory structure table 430 . An exemplary dynamic entry into directory structure table may relate to the name of the content-dependent module responsible for the identification of tasks existing in the system at any given point in time.
[0047] Thus, in exemplary FIG. 4, the dynamic name in box 469 a (/#/fd/#) represents the name (including the directory path name and the file name) registered by content-dependent module 441 associated with file descriptor subsystem 410 . The dynamic name in box 470 a (/#/fd) represents the name (including the directory path name and the file name) registered by content-dependent module 440 associated with file descriptor subsystem 410 . The dynamic name in box 472 a (/#) represents the name (including the directory path name and the file name) registered by the content-dependent module 444 associated with the task/process subsystem 414 . The dynamic name in box 474 a (/#/cmd) represents the name (including the directory path name and the file name) registered by content-dependent module 446 associated with task/process subsystem 414 . The dynamic name in box 476 a (/#/lwp) represents the name (including the directory path name and the file name) registered by the content-dependent module 448 associated with the task/process subsystem 414 . The dynamic name in box 478 a (I#/lwp/#) represents the name (including the directory path name and the file name) registered by the content-dependent module 450 associated with task/process subsystem 414 . The dynamic name associated with box 482 a (/#/mem) represents the name (including the directory path name and the file name) registered by content-dependent module 452 associated with virtual memory subsystem 416 . 48 In box 480 a , a static name is registered. In this case, the static name /sys/loadavg represents the name (including the directory path name and the file name) registered by content-dependent module 442 associated with scheduler subsystem 412 . Since this name is known at the time it is registered with the directory structure table 430 , it is registered as a static name therein.
[0048] As one example, suppose the application wants to read the file with the name /proc/3/fd/2. This name contains four indivisible components (proc, 3, fd, and 2). The virtual file system and virtual ProcFS layer perform lookups using these components. Look up of the first component (“proc”) by the virtual file system 404 will indicate that further lookup operations should be performed by the virtual ProcFS layer 406 , which will eventually forward lookups to the content-dependent modules. Within the virtual ProcFS layer, the name “3/fd/2” is represented three distinct entries in the directory structure table. These entries are shown in box 472 a , 470 a , and 469 a respectively. Accordingly, the second component (“3”) will be handled by module 444 . The third component (“fd”) will be handled by module 440 , and the fourth component (“2”) will be handled by module 441 .
[0049] [0049]FIG. 5 a shows a virtual ProcFS layer view of an exemplary directory structure as registered by the content-dependent modules. FIG. 5 b shows the application view of the same exemplary directory structure. In FIG. 5 a , the name space is established at the time of registration, but many of the actual names (including exact paths and exact module names) are not known at registration time. For example, in the exemplary directory structure of FIG. 5 a , the module name “net” 510 represents a static entry into the directory structure table since the name is known at the time of registration with the directory structure table. Likewise, the module name “mounts” ( 512 ) represents another static entry into the directory structure table.
[0050] However, the entry 514 is a dynamic entry, and more specifically a dynamic name for a directory. For every instance of subdirectory 514 (represented by the #/), there is a file called “map” ( 520 ), a file name “status” ( 522 ) and a subdirectory “fd/” ( 524 ). Map 520 provides information pertaining to the memory map of the task/process. Status 522 furnishes information pertaining to the status of a process. Status can relate to, for example, how much time the task has been running, what is the status of the task, and the like.
[0051] In the example of FIG. 5 a , subdirectory “fd/” relates to file descriptors and gives information pertaining to how many files have been opened. Since the number of files opened during execution is not known at registration time, the exact names of the open files are represented by a dynamic entry, which is shown by reference number 526 .
[0052] [0052]FIG. 5 b shows the same view of FIG. 5 a except that the view in FIG. 5 b represents what the application sees at an arbitrary point in time during execution after the virtual ProcFS layer consults the directory structure table. Note that FIG. 5 b shows a snapshot of all the instances of dynamic entries, which is often not the case as the virtual ProcFS layer may consult and instantiate the names for only a subset of the entries in the directory structure table at any given point in time during execution.
[0053] In FIG. 5 b , the static entries 510 and 512 are as discussed in connection with FIG. 5 a . There are three instances of dynamic subdirectory 514 , which are shown by reference numbers 550 , 552 and 554 of FIG. 5 b . Each instance of dynamic subdirectory 514 includes all the files/subdirectories under that subdirectory instance, which are shown in FIG. 5 a by reference numbers 520 , 522 , 524 and 526 . Thus, the dynamic directory instance 550 includes a map file 560 , a status file 562 , and a file descriptor subdirectory 564 containing file descriptor files of which there are X number of instances (shown by reference numbers 566 , 568 and 570 ). The dynamic directory instance 55 w includes a map file 572 , a status file 574 , and a file descriptor subdirectory 576 containing file descriptor files of which there are Y number of instances (shown by reference numbers 578 , 580 and 582 ). The dynamic directory instance 554 includes a map file 584 , a status file 586 , and a file descriptor subdirectory 588 containing file descriptor files of which there are Z number of instances (shown by reference numbers 590 , 592 and 594 ). In this example, X, Y, and Z can be any arbitrary number of integers and although only three instances of the dynamic subdirectory 514 is shown in FIG. 5 b , there may be any number of dynamic directory instances. Also, the enumerations derived from the dynamic names do not need to be sequential at all points in time as instances are created and removed from time to time.
[0054] Note that in FIG. 5 b , although there are three instances of the map files (shown by reference numbers 560 , 572 and 584 ) for the three instances of the dynamic subdirectory 514 , the contents of each of these map files may be different because they are associated with different processes altogether.
[0055] In accordance with one aspect of the present invention, support module 462 also keeps track of the parent and grandparent of a particular content-dependent module so that the context can be known when the exact module name instances are dynamically generated. The tracking by support module 462 starts when the application opens a specific instance of the file. For example, the module supporting map when acting on instance 572 must be provided the information that it is within the context of process 2 (reference number 552 ). The context information is created at the time the specific instance is opened, and employed for subsequent operations on that file until closed.
[0056] It is believed that the Linux process file system support the concept of a pseudo-virtual ProcFS layer, which supports static entries (i.e., the addition, deletion and/or modification thereof) whose names are known at the time of registration. It also supports limited operation in the interface between the pseudo-virtual ProcFS layer and the content-dependent modules. However, the Linux process file system does not support dynamic entries and dynamic hierarchies. This information must be built into the pseudo-virtual ProcFS layer of the Linux process file system. Also the operations handled through the interface between the pseudo-virtual ProcFS layer and the content-dependent modules of the Linux process file system do not include name lookups and other control operations. These limitations mean that the Linux process file system cannot support a fully decoupled ProcFS system, as disclosed herein, in which the virtual ProcFS layer can access the modules in an entirely content-independent manner and the content-specific information is encapsulated within the content-dependent modules.
[0057] [0057]FIG. 6 is a symbolic diagram showing that due to the partitioning of the ProcFS into the virtual ProcFS layer and the content-dependent layer, the use of the common interface, and the ability to allow content-dependent modules whose names may not be known at the time of registration to register and used by the ProcFS layer, it is possible for the ISV supplied module 602 to be dynamically loaded into ProcFS 604 independently, the ProcFS management module 606 to be dynamically loaded into ProcFS 604 independently, and the virtual memory content-dependent module 608 to be dynamically loaded into ProcFS 604 independently.
[0058] These dynamically loaded modules 602 , 606 and 608 , when written to conform with the requirement of the common interface 610 , can communicate with the virtual ProcFS layer 612 in a substantially data decoupled manner. A change in one of the kernel subsystems would require a corresponding change only in its associated content-dependent module without impacting either a virtual ProcFS layer 612 , other content-dependent modules, the remainder of the directory structure table, or the support module.
[0059] It is not necessary for any single team to know the details regarding the content, format, and directory hierarchy associated with any other module other than the one which that team is responsible for. Also, it is not required for any single team to coordinate the effort with other teams in order to come up with an updated ProcFS system. Accordingly, any change to the ProcFS can be accomplished with minimal transaction cost and delay, enhancing customer satisfaction.
[0060] The data coupling issue of the prior art is substantially eliminated by the use of the common interface and the virtual ProcFS layer, which does not require any knowledge of the details of the content and format of the various internal kernel data structures. Thus, individual content-dependent modules associated with individual kernel subsystem can be updated and/or dynamically loaded into the ProcFS at any time and the dynamic scheme of name registration allows the modules to register without requiring any advance knowledge of the execution-time name.
[0061] While this invention has been described in terms of several preferred embodiments, there are alterations, permutations, and equivalents which fall within the scope of this invention. For example, although the invention has been described in the context of a UNIX example, the inventive methods and apparatus also apply to other operating system environments, such as Linux, Windows, and the like. As another example, although the specific exemplary implementation discussed herein positions the virtual ProcFS layer and/or the content-dependent modules in the OS kernel space, the invention also applies to situations where the virtual ProcFS layer and/or the content-dependent modules are implemented in the user/application space or in a combination thereof. As another example, although the specific embodiments discussed herein show a virtual file system layer, the use of such a virtual file system layer, such as virtual file system 404 of FIG. 4 is not absolutely necessary to practice the invention herein. As a further example, although the use of a special symbol is employed to denote that an entry is a dynamic name, other techniques (such as using a flag) can also be used to signify that a particular entry is dynamic. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall 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 yard hydrants and more particularly to a valve for a hydrant structure which utilizes a movable spout head in place of a separate traditional type operating handle for opening and closing the flow of water through the hydrant head.
2. Description of the Prior Art
Hydrants have long been used in connection with water systems and much of the basic hydrant art appears to lie in the late 1800's and early 1900's. In such early art and even in later improvements it would appear that the hydrant device includes basically a fixed hydrant head for release of water with some suitable valve structure regulating the flow of water to the head and an appropriate operating handle for controlling the movement of the valve components. Such handle means frequently used a swingable type handle or a rotatable knob and various structures to control the volume of flow control though the valve and hydrant.
U.S. Pat. No. 3,523,549 to Noel Anderson shows a hydrant of the general type used in this invention using a reciprocating valve that is shut off when it is raised and turned on when it is lowered, water pressure biasing the valve to a closed position so that it will not continue to run if someone forgets to turn it off. U.S. Pat. No. 3,672,392 to Noel Anderson is similar to the '549 patent except that it primarily uses a different structure to move the hydrant head up to the closed position or down to the open position. U.S. Pat. No. 6,178,988 to Royle is similar to the two Anderson patents in that the hydrant head is moved up or down to control the flow but it uses a spool valve instead of the type of valve used in the Anderson patents and in Royle, when the hydrant head is up there is flow through the hydrant head and when the hydrant head is down the valve is shut off to high pressure but allowing the hydrant to drain to a level below the frost line to prevent freezing. All three of these aforementioned prior art devices use valves that reciprocate in a bore that is of a uniform diameter everywhere that the valve body moves therein to allow of the respective valve body to seal against the inside walls of the bore in the valve housing, thereby limiting the amount of flow through the respective valves at times when more flow is desired.
BRIEF SUMMARY OF THE INVENTION
The present invention utilizes a reciprocating valve for controlling the flow in a hydrant flow pipe vertically movable within a standpipe. The lower end of the flow pipe is provided with a novel valve for controlling the flow of water therethrough from a water supply under pressure. The upper end of the flow pipe is fixedly secured to the hydrant spout head and in flow communication therewith and such head is vertically movable with the flow pipe and valve relative to the standpipe. When the hydrant head is down, flow of water from a source of high pressure below the frost line is off. Contact of water under pressure with the valve will tend to bias the valve towards the open position with the flow pipe and hydrant head being elevated accordingly during the open position of the valve. Closing of the valve on the flow pipe for the passage of water to the hydrant head is accomplished by lowering the hydrant head with respect to the standpipe and the ground, which correspondingly lowers the flow pipe and valve body to the closed position while simultaneously allowing the water in the hydrant head, flow pipe and valve to drain to below the frost line to prevent freezing.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a partial cross sectional view of a yard hydrant constructed in accordance with the present invention, showing the yard hydrant in the closed position thereof;
FIG. 2 is a partial cross sectional view of the yard hydrant of FIG. 1 of the present invention, but showing the yard hydrant in the open position thereof;
FIG. 3 is an enlarged cross sectional view of the valve portion of the present invention in the closed position thereof;
FIG. 4 is a perspective view of the valve body that reciprocates inside of the valve housing shown in FIGS. 1-3 and 5 ; and
FIG. 5 is an enlarged cross sectional view of the valve portion of the present invention like that shown in FIG. 3 except that it is shown in the open position.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, FIGS. 1 and 2 show a yard hydrant 10 constructed in accordance with the present invention. A valve housing ( 11 ) adapted to be connected at one end to a source of fluid under pressure at the bottom threads ( 11 tb ).
A valve housing ( 11 ) has a first portion ( 11 a ) with a first inside diameter, a second portion ( 11 b ) with a second inside diameter that is larger than the first inside diameter ( 11 a ) and a third portion ( 11 c ) between the first and second portions with a third inside diameter that is larger than the second inside diameter.
Still looking at FIGS. 1 and 2 , a standpipe ( 12 ) having an upper and lower end with the lower end secured to the other end of the valve housing ( 11 ) at the threaded top portion ( 11 tt ) of the valve housing ( 11 ). A flow pipe ( 13 ) is concentrically disposed within the standpipe ( 12 ) and is reciprocal therein.
A valve body ( 14 ) is disposed inside of the valve housing ( 11 ), the valve body ( 14 ) being closed at the bottom end ( 14 x ) thereof and having an open interior ( 14 i ) in fluid communication at all times with the flow pipe ( 13 ). The valve body ( 14 ) has a port ( 14 p ) in fluid communication at all times with an interior of the third inside portion ( 11 c ) of the valve housing ( 11 ). The valve body ( 14 ) has a first body portion ( 14 a ) with a first outside diameter that will fit in close sliding relationship with the first inside diameter of the first portion ( 11 a ) of the valve housing ( 11 ). A second body portion ( 14 b ) has a second outside body diameter that will fit in close sliding relationship with the second inside diameter of the second housing portion ( 11 b ) of the valve housing ( 11 ). Similarly, a third body portion ( 14 c ) that has approximately the same outside diameter as the second outside body diameter of the second body portion ( 14 b ) is provided so that the second ( 14 b ) and third ( 14 c ) body portions can slide in close sealing relationship with the second inside housing portion ( 11 b ). The valve body ( 14 ) also has a fourth body portion ( 14 d ) located between the second ( 14 b ) and third ( 14 c ) body portions. This fourth body portion ( 14 d ) has an outside diameter which is less than the outside diameter of the second ( 14 b ) and third ( 14 ) body portions of the valve body ( 14 ).
The valve body ( 14 ) is operatively attached to one end of the flow pipe ( 13 ) and by selective reciprocation of the flow pipe ( 13 ) as shown in FIGS. 1 and 2 . The valve body ( 14 ) has a closed position shown in FIG. 1 for preventing fluid communication between the source of fluid under pressure at threads ( 11 t ) and the flow pipe ( 13 ) when the first portion ( 14 a ) of the valve body ( 14 ) is in the first portion ( 11 a ) of the valve housing ( 11 ). FIG. 2 shows the valve body ( 14 ) in an open position when the first portion ( 14 a ) of the valve body ( 14 ) is raised out of the first portion ( 11 a ) of the valve housing ( 11 ) to the third portion ( 11 c ) of the valve housing ( 11 ) to permit fluid communication from the source of fluid pressure to enter the third portion ( 11 c ) of the valve housing. From there to the fluid flows through port ( 14 p ) in valve body ( 14 ), from there to the open interior of the valve body ( 14 i ), from there to the open interior of the valve body ( 14 i ) and then on to the flow pipe ( 13 ).
A hydrant head ( 16 ) operatively attached at one end thereof to the other end of the flow pipe ( 13 ) and in flow communication therewith. The hydrant head ( 16 ) has an outlet ( 16 b ) for directing flow from the flow pipe ( 13 ) from the hydrant inlet ( 16 a ) when the valve body ( 14 ) is in the open position thereof. The hydrant head ( 16 ) is slidably journalled on the upper end of the standpipe ( 12 ) as shown in FIGS. 1 and 2 so that movement of the hydrant head ( 16 ) in one direction acts to move the flow pipe ( 13 ) and valve body ( 14 ) to the open position to allow flow communication with the source of fluid under pressure as shown in FIG. 2 and movement of the hydrant head ( 16 ) in the opposite direction acting to move the flow pipe ( 13 ) and valve body ( 14 ) to the closed position of the valve body to prevent fluid communication with the source of fluid under pressure is shown in FIG. 1 .
A drain port ( 11 d ) is in fluid communication with an inside part of the second portion ( 11 b ) of the valve housing ( 11 ) for permitting fluid communication between the inside of the valve housing ( 11 ) and the outside of the valve housing ( 11 ) when the valve body ( 14 ) is in the closed position of FIG. 1 , thereby allowing fluid to drain from the hydrant head ( 16 ) and flow pipe ( 13 ) when the valve body ( 14 ) is closed. This is important to keep the water above the frost line from freezing in the wintertime.
A shoulder ( 14 s ) on the second portion ( 14 b ) of the valve body ( 14 ) is in contact with a top portion ( 11 t ) of the first portion of the valve body ( 14 ) when the valve body ( 14 ) is in the closed position shown in FIG. 1 .
The first portion ( 14 a ) of the valve body ( 14 ) has two O-rings ( 14 as) in respective annular grooves for sealing against a surface of the inside diameter of the first portion ( 11 a ) of the valve housing ( 11 ). The second portion ( 14 b ) of the valve body ( 14 ) has two O-rings ( 14 bs ) in respective annular grooves for sealing against a surface of the inside diameter of the second portion ( 11 b ) of the valve housing ( 11 ).
Looking again at FIGS. 1 and 2 , the yard hydrant ( 10 ) has a collar ( 17 ) rigidly fixed to the standpipe ( 12 ). A handle ( 18 ) is pivotally attached to the hydrant head ( 16 ) at pin ( 20 ). A link ( 19 ) is operatively pivotally attached at one end to a handle ( 18 ) at pin ( 21 ) and at another end thereof to the collar ( 17 ) at pin ( 22 ).
The handle ( 18 ) has a first pivotal position ( FIG. 1 ) corresponding to the closed position of the valve body ( 14 ) and a second pivotal position ( FIG. 2 ) corresponding to the open position of the valve body ( 14 ). The handle ( 18 ) has a surface ( 18 c ) which is, when the valve is closed, in abutment with a surface ( 16 c ) on the hydrant head ( 16 ) for holding the handle ( 18 ) in the closed position shown in FIG. 1 until the handle ( 18 ) is moved to the open position thereof as shown in FIG. 2 . Moving the handle ( 18 ) from the open position shown in FIG. 2 to the closed position shown in FIG. 1 causes the over center condition shown in FIG. 1 to securely hold the handle ( 18 ) in the closed position until it is manually pivotally forced again towards the open position shown in FIG. 2 .
Arrows shown in FIGS. 2 and 5 illustrate the flow of fluid such as water when the valve body ( 14 ) is in the raised/open position and the arrows in FIGS. 1 and 3 show the closed position of the valve but still allowing drainage of water from the hydrant head ( 16 ), flow pipe ( 13 ) and valve body ( 14 ) out through the drain hole ( 11 d ) to keep the hydrant from freezing in the wintertime when the hydrant is installed such that the valve housing ( 11 ) is in the ground below the frost line.
In FIGS. 1 and 2 a locking hole ( 23 a ) in the hydrant head ( 16 ) aligns with a locking hole ( 23 b ) in the handle ( 18 ) in the closed position of FIG. 1 , to permit a padlock or the like to pass through the aligned locking holes ( 23 a ) and ( 23 b ) if desired.
Obviously many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | 4y
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FIELD OF THE INVENTION
The present invention relates to a speed control device for motor vehicles, having a controller and a user interface, as well as to a motor vehicle having such a speed control device.
BACKGROUND INFORMATION
Within the scope of a vehicle speed controller, known speed control devices enable one to control the speed of one's own vehicle to a desired speed selected by the driver. Furthermore, advanced speed control devices are known, so-called ACC systems (adaptive cruise control), which are additionally in a position to find the position of a vehicle traveling ahead in one's own lane with the aid of a radar sensor or a comparable position-finding system, to measure its distance ahead and its relative speed, and then, by an intervention in the drive system and possibly also the braking system of one's own vehicle, to control the speed in such a way that the preceding vehicle is followed at an appropriately safe distance.
Within the scope of the speed control or distance control, if a setpoint/actual deviation occurs, a control strategy will be required which determines in which manner, and at which curve over time, the actual value should be brought back to the setpoint value. Parameters which determine this control strategy in a determinative way are, for example, the upper and the lower boundary values for the acceleration of one's own vehicle. The upper boundary value determines the maximum vehicle acceleration which is to be demanded of the drive system of the vehicle, within the scope of the control, and the (negative) lower boundary value determines the maximum deceleration at which the vehicle is to be decelerated. Other parameters may, for example, establish under what conditions an intervention in the braking system is to take place.
In the establishment of these parameters, various objectives should be considered which, in part, may be contradictory to one another. For one thing, of course, the necessary traffic safety should be ensured. In addition, a manner of travel should be achieved that is as comfortable as possible for the driver and the passengers, and which is also as fuel saving as possible. On the other hand, however, the flow of traffic should also not be impeded unnecessarily, and the system behavior should correspond to the greatest extent possible to the intuitive driving behavior of a human driver. If, for instance, a slower preceding vehicle is being followed on the passing lane of an expressway, and this vehicle then changes lanes to the right neighboring lane, one's own vehicle should then be accelerated again to the desired speed as quickly as possible, so that the passing procedure of one's own vehicle is shortened and the following traffic is not impeded. Up to this point, the establishment of the parameters determining the control strategy is based on a compromise between the various objectives.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a speed control device that permits a particularly fuel saving manner of driving.
This object is attained, according to the present invention, in that, in the controller, several operating modes are implemented which differ in their control strategies, and which include at least one eco mode whose control strategy is optimized for a fuel saving manner of driving, and in that the user interface has an input device for selecting the operating mode.
Under certain conditions, for instance, as a function of his current priorities or as a function of the traffic situation, this gives the driver the possibility of selecting a particularly fuel saving operating mode that will be designated below as the eco mode. In this operating mode, in general, the control strategy will be characterized by a low upper limit and a high lower limit for the acceleration.
The present invention is particularly advantageous in the case of motor vehicles that have hybrid drive.
In a hybrid drive, besides an internal combustion engine, an electric motor is provided to generate the propulsive power, which is fed by a rechargeable battery. In response to a deceleration of the vehicle, the electric motor may also be operated as a brake/generator, so that a part of the energy of motion is able to be recaptured and stored in the battery. An intelligent drive management provides that the internal combustion engine is operated as often as possible and as long as possible at its optimum operating point, at which it works at the highest efficiency. If the performance of the internal combustion engine is not sufficient in this state, the missing performance is provided by the electric drive, whereas reversely speaking, excess power is able to be used for recharging the battery. Because of this drive concept, fuel usage is clearly able to be reduced.
Now, the present invention permits the driver to select an eco mode in which the control strategy is matched optimally to the requirements of the hybrid drive. In this mode, for example, the upper boundary for the acceleration may be established in such a way that the required drive power is able to be provided by the electric drive, and consequently, the internal combustion engine does not have to leave its optimum operating point. Likewise, the lower boundary for the acceleration may be established in such a way that, in response to deceleration, energy of motion becoming free is able to be completely converted by the generator into electrical energy, so that no energy is lost by the activation of friction brakes.
In case of need, for instance, if, at a higher traffic density, a more dynamic manner of driving is indicated, so that changing lanes on multi-lane roadways may be undertaken without danger, the driver may switch over at any time to the “normal” operating mode, in which higher vehicle accelerations and decelerations are permitted.
It is true that in the eco mode, in the normal case, the upper acceleration limit will be reduced compared to the normal mode, but there may also be situations in which fuel savings will be achieved by permitting a greater acceleration than in the normal mode. In the case of a hybrid drive this is, for example, the case if the acceleration appropriate for the traffic situation is so great that the required additional power cannot be provided by the electric drive, so that the internal combustion engine has to work away from its optimum operating point. In this case, it may be expedient to increase the acceleration further, so that the vehicle attains its setpoint speed more rapidly, and the internal combustion engine returns again to its optimal operating point, correspondingly earlier.
When driving at approximately constant speed, under certain circumstances it may be expedient to vary the setpoint speed, especially to lower it, if thereby an unfavorable operating state, such as shifting down to a lower gear step, is avoidable. Conversely, in other situations fuel savings may be achieved by a slight increase in the setpoint speed, for instance, when it thereby makes possible shifting to a higher gear.
An increase in the setpoint speed beyond the desired speed selected by the driver is problematic, however, because the driver has possibly selected this desired speed to respect an existing speed restriction. If, for the purpose of fuel savings, it is required in the eco mode to increase the setpoint speed beyond the desired speed, the driver should receive a warning notice on this, or the increase should only be admissible if the driver confirms a query output by the system in this regard.
The parameters characterizing the control strategy, for example, the upper and the lower boundaries for the acceleration, may also vary as a function of the situation, for instance, as a function of the slope of the roadway, the payload of the vehicle and the like.
In general, the deviations of the acceleration boundaries and the setpoint speeds, that are valid in the eco mode, from the corresponding acceleration boundaries and setpoint speeds in normal operating mode should not exceed a certain measure, for example 10%, so that the vehicle's behavior remains determined for the driver, and no unexpected accelerations or decelerations occur.
In the eco mode matched to the hybrid drive, the control strategy may also be a function of the charge state of the battery. For instance, at a low charge state of the battery, the setpoint speed may be reduced, so that a certain excess power of the internal combustion engine is available for the recharging of the battery.
In known ACC systems, a so-called dip-in strategy is also a component of the control strategy, which determines, when approaching a slower preceding vehicle, how far one's own vehicle may “dip into” an appropriate safety distance. This dip-in strategy may also differ in the eco mode from that in the normal mode. Within the scope of the distance control, the setpoint distance is typically dependent on the speed, and it is determined by a time gap, selectable by the driver within certain limits, which gives the distance in time between the preceding vehicle and one's own vehicle. In the eco mode it may be expedient to enlarge this time gap, so that more play is available for the dip-in strategy.
In the case of vehicles having hybrid drive, a meaningful collaboration between the speed control device and the drive management should be striven for. This cooperation may expediently be designed so that the drive management makes the decisions on the selection of the drive source, the selection of the gear step and the like, and the speed control device always receives a status message from the drive management when it would be possible to achieve significant fuel savings by the modification of the setpoint acceleration and/or the setpoint speed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block diagram of a speed control device according to the present invention.
FIG. 2 shows a diagram to illustrate different control strategies.
FIG. 3 shows a speed/time diagram for illustrating the effect of different control strategies.
DETAILED DESCRIPTION
FIG. 1 shows as an example of a speed control device, according to the present invention, an ACC system for a vehicle having hybrid drive. An electronic control unit 10 includes a controller 12 for speed control and distance control, and a drive management system 14 , which communicate with one another via a bus system 16 , as well as with an interface unit 18 and a program and parameter memory 20 . Interface unit 18 receives position finding data for the distance control from a radar sensor 22 , built into the vehicle, as well as a signal from a speed measurement unit 24 of the vehicle, which states the actual speed V of one's own vehicle. In addition, a user interface 26 is connected to interface unit 18 , and it has a display 28 and an acoustical output device in the form of a loudspeaker 30 , for outputting information to the driver. In addition, user interface 26 includes an input device 32 , formed by one or more switches, via which the driver is able to input operating commands.
Drive management system 14 controls the hybrid drive of the vehicle, which includes an electromechanical converter which is able to operate both as an electric motor 36 and a generator 38 . In the example shown, drive management system 14 also engages with brake system 40 of the vehicle. When a braking command is given by controller 12 or by the driver himself, drive management system 14 decides whether the necessary braking deceleration is able to be attained only with the aid of generator 38 , or whether in addition, the usual braking system 40 of the vehicle, that is based on friction brakes, has to be activated.
With the aid of data supplied by radar sensor 22 and by speedometer 24 , as well as possibly with the aid of certain additional information on the state of the vehicle, for instance, the yaw rate, controller 12 , in a known manner, calculates a setpoint acceleration a, which forms the basis for the intervention in the drive system and/or the braking system of the vehicle. In the example shown here, this setpoint acceleration is passed on directly to drive management system 14 , which then decides how the requested acceleration or deceleration is able to be attained in the most favorable consumption manner.
In program and parameter memory 20 parameter sets and possibly program modules are stored, which controller 12 accesses via bus system 16 , and which specify different operating modes in which controller 12 is able to operate. One of these operating modes is a normal operating mode N, which corresponds to the usual function of an ACC system. The other operating mode is an eco mode E, which is optimized to as fuel consumption-favorable as possible a driving manner, while taking into consideration the properties of the hybrid drive (within certain limits). In particular, the parameter sets, stored in program and parameter memory 20 , specify for each operating mode an upper limit a_max_N and a_max_E, as well as a lower limit a_min_N and a_min-E for setpoint acceleration a, which is able to be output to drive management 14 . The lower limits are negative and consequently state the maximum deceleration of the vehicle that is admissible in each case.
As shown in FIG. 2 , upper limit a_max_E for the acceleration in eco mode E is smaller than the corresponding upper limit in normal mode N, and lower limit a_min_E in eco mode E is greater than the corresponding lower limit in normal mode N. Consequently, in eco mode E the admissible acceleration range is more restricted, whereby a fuel-saving manner of driving is achieved. The limits in the eco mode are especially selected so that the corresponding acceleration or deceleration is able to be attained if possible with the aid of electric motor 36 or generator 38 , without internal combustion engine 34 having to leave its optimum operating point.
However, under certain circumstances a greater upper limit a_max_E′ may also apply in eco mode E for the acceleration, which is even higher than the upper limit in normal mode N. This is the case, for example, if the setpoint speed is substantially greater than the instantaneous actual speed, and therefore a “sensible” acceleration of the vehicle would have to be so great that the transmission would have to be shifted down by one gear and/or a greater performance would have to be required of internal combustion engine 34 than at its optimal operating point. In that case, the greater acceleration has the effect that the setpoint speed is attained more rapidly, and thus the favorable fuel usage state lasts only a relatively short time, so that fuel savings come about overall.
FIG. 3 illustrates the system behavior with the aid of a speed/time diagram. The dashed curve marked N shows the speed curve in normal operating mode N, while the line that is plotted in a continuous line and denoted by E gives the corresponding speed curve in eco mode E.
Between times t 1 and t 2 the acceleration in eco mode E is smaller than in normal mode N, so that the acceleration phase lasts correspondingly longer. v_lim denotes a limiting speed which under the current operating conditions requires switching the drive system into another operating state. At a speed barely above v_lim, the fuel usage would be significantly higher than at a speed barely below this boundary value. For this reason, it is provided on eco mode E that between times t 2 and t 3 the setpoint speed, deviating from the desired speed selected by the driver, is reduced to a value below v_lim, so that one may take advantage of the fuel savings. Naturally, this applies only in the cases in which the desired speed selected by the driver is only slightly above v_lim.
At time t 3 , radar sensor 22 , whose position-finding depth is, for example, 150 m, finds the position of a slower preceding vehicle. In eco mode E, the deceleration of the vehicle then sets in without delay, but at a relatively low deceleration rate. In normal mode N, by contrast, one pulls up closer to the preceding vehicle before the deceleration begins, but then at a greater deceleration rate. In the example shown, the new setpoint speed, which corresponds to the speed of the preceding vehicle, is reached in eco mode E only at time t 4 , whereas in normal mode N it would already be reached at an earlier point in time. This means that in eco mode E a slight and temporary falling below of the setpoint distance from the preceding vehicle is permitted earlier than in normal mode N.
At time t 5 the preceding vehicle has changed to a side lane, so that the roadway is free again. Besides that, the driver has meanwhile clearly increased the desired speed. In this case, the acceleration rate in eco mode E corresponds to the increased upper limit a_max_E′ in FIG. 2 , so that the new desired speed is reached already at time t 6 , while in normal mode N the acceleration phase would be prolonged.
Controller 12 is preferably configured in such a way that it works in response to the activation of the ACC system in eco mode E. However, the driver is able to switch over at any time to normal mode N, and switch back again to eco mode E via operating device 32 . | 4y
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TECHNICAL FIELD
This invention relates generally to protecting a surface from damage by vehicle tires and more particularly to a novel surface anti-scuff device and system for vehicle tires.
Background Art
There are many surfaces over which vehicles are moved which can be severely damaged by the mars and scuffs provided by vehicle tires. There is a need for an effective anti-scuff device and system that will prevent scuffing or marring of a Surface when a vehicle is moved or driven over a surface. For example, scuffing and marring of surfaces results in expensive and extensive clean up for contractors on many construction jobsites. Smooth concrete is one example of a surface that is easily damaged by such vehicle travel. Vehicle travel frequently results in black marks on a variety of types of flooring. A technique presently in use is to wrap duct tape over the tire tread. A disadvantage of this approach is difficulty in removing the tape and frequently the glue on the tape is transmitted to the surface.
Disclosure of the Invention
In accordance with the present invention, there is provided a surface anti-scuff device including an anti-scuff member that readily mounts onto and demounts from a tire and on the tire extends around the circumference and a portion of the sides thereof and is fastened tightly to the tire as by draw strings so that during movement over the surface the tire cannot scuff or mar or substantially prevents scuffing of the surface over which the tire is driven. In an anti-scuff system for vehicles each tire of the vehicle is provided with a similar surface anti-scuff device.
BRIEF DESCRIPTION OF THE DRAWINGS
Details of this invention are described in connection with the accompanying drawings which like parts bear similar reference numerals in which:
FIG. 1 is a perspective view of a four wheeled vehicle with each tire equipped with an anti-scuff device embodying features of the present invention.
FIG. 2 is an enlarged perspective view of one of the tires and anti-scuff device shown in FIG. 1.
FIG. 3 is a perspective view of an anti-scuff device in a flat condition prior to assembly to the tire.
FIG. 4 is an enlarged inside elevation view of a corner portion of the draw line assembly at the connected ends of the strip of material.
FIG. 5 is a side elevation view of the device shown in FIG. 2.
FIG. 6 is a sectional view taken along line 6--6 of FIG. 5.
FIG. 7 is a sectional view taken along line 7--7 of FIG. 5.
FIG. 8 is a perspective view of an alternative embodiment of an anti-scuff device.
FIG. 9 is a sectional view taken along line 9--9 of FIG. 8.
DETAILED DESCRIPTION
Referring now to the drawings there is shown in FIG. 1 a wheeled vehicle 9 having four wheels each with a tire 10. This vehicle 9 is illustrative of any type of motorized or non-motorized vehicle that may be moved over a supporting surface 11. Each tire 10 has an anti-scuff device 12 mounted thereon to provide a surface anti-scuff system for the vehicle 9. Each surface anti-scuff device 12 includes an anti-scuff or non-scuffing member 14 shown in the form of a single rectangular strip of material of a preselected width and length that is sized according to tire size that is wider than the tire tread so it will overlay the tire tread and a portion of each sidewall of the tire with the strip being fastened to the tire along both sides. The strip is secured at the ends by folding the opposite end portions 14a and 14b of the strip 14 against one another and securing them as with stitching 15 to form the strip 14 into a closed loop having substantially the same circumference as the circumference of the tire to which it is secured.
A first folded side edge portion 16 is provided along an inner side edge of the material 14 and a second folded side edge portion 18 is provided along the opposite outer side edge of the material. These edge portions 16 and 18 are formed as by stitching at lines 22 and 24, respectively. A first draw line 26 is provided in the first folded edge portion 16 and a second draw line 28 is provided in the second folded side edge portion so that the draw lines 26 and 28 can be used to draw the strip of material 14 tightly against the circumference and portion as of the sidewalls on both sides of the tread of the tire. The opposite end portions of the draw lines are shown held by a conventional line clamp 29 having a hole through which two of the draw lines extend and a spring biased button that releases when depressed. The draw lines could also be tied in a suitable, readily releasable knot.
At each end of each folded side edge portion and at the connected end portions 14a and 14b a corner portion 31 of the material is folded over and secured as by stitching 32 to provide a double-thickness beveled edge portion 33. This enables each draw string to be pulled on a straight line so there is uniform pull and no bunching up of the material.
A material found suitable for this anti-scuff member 14 is CORDURA® PLUS manufactured by DuPont Company. This product is a pliable, tightly woven nylon, preferably a plain weave that will readily conform to the exterior surface of the tread and sidewalls of the tire and is provided with an inside coating or layer to make it water resistant. It is found that if this strip is held tightly to the tire,tread and along the sides that vehicles with rubber tires can be driven over a surface to prevent or substantially prevent scuffing the surface or without significantly scuffing the surface.
An alternative embodiment shown in FIGS. 8 and 9 has a stretchable strip of material 42 of a suitable elastic material fastened at and between folded end portions of the anti-scuff member 14 to enable the closed loop to stretch slightly over a limited width. This stretchable strip of material 42 is shown sewn to the ends as by stitching indicated at 43.
Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example and that changes in details of structure may be made without departing from the spirit thereof. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to low dielectric constant substrates comprising cordierite and methods for forming the low dielectric constant substrates.
The low dielectric constant substrates of the present invention find particular application in forming multilayer ceramic materials.
The substrates may be designed with termination pads for attaching semiconductor chips, connector leads, capacitors, resistors, covers, etc. Three dimensional current networks may be produced using the so-called MLC or multilayer ceramic process in which horizontal circuit patterns that are thick film screened on unsintered or green sheets are connected by using vertical interconnections or vias formed by metal paste filled holes. Individual layers are then laminated and then sintered forming a sintered, dense ceramic/metal package.
2. Description of the Prior Art
A relatively recent innovation in electronic packaging has been the development of the multilayer ceramic (hereafter often MLC) module. In this technology, "green" sheets of ceramic powder held together by a temporary organic binder are metallized with a noble or refractory metal, usually, but not mandatorily, by screen printing. The metallized sheets are stacked, laminated and fired to form a monolithic ceramic-metal package. Details on MLC technology are given in SOLID STATE TECHNOLOGY, May, 1972, Vol. 15, No. 5, pages 35-40, Kaiser et al, hereby incorporated by reference, and U.S. Pat. No. 2,966,719, also hereby incorporated by reference.
Additional procedures for forming laminated green sheets for fabricating multilayer substrates are also disclosed in U.S. Pat. Nos. 3,423,517 and 3,723,176, both hereby incorporated by reference.
IBM Technical Disclosure Bulletin, Vol. 16, No. 4, September, 1973, page 1282, discloses a method of depositing thick gold lines over interconnection metallurgy located on a ceramic substrate. Molybdenum interconnection patterns and via paths are disclosed.
IBM Technical Disclosure Bulletin, Vol. 19, No. 4, September, 1976, page 1259, discloses a plated ceramic module. A layer of ceramic is coated with fritted molybdenum which in turn is coated with a layer of molybdenum to insure a continuous plating of nickel that can be diffused into the entire molybdenum layer.
IBM Technical Disclosure Bulletin, Vol. 19, No. 10, March, 1977, page 3777, discloses the use of high-density sintered molybdenum for internal circuit patterns and for the top and bottom side metallurgy of multilayer ceramic modules. Since the molybdenum is subject to corrosion problems, it is protected during the sintering operation by forming a corrosion-resistant nickel-molybdenum layer thereon.
U.S. Pat. No. 2,731,355 to Skinner discloses magnesium-aluminum-silicate compositions and methods of preparing the same. More particularly, Skinner relates to compositions of this type having high crystalline cordierite development and to methods of producing the same. The compositions are stated to have good electrical properties and low thermal expansion.
U.S. Pat. No. 2,864,919 to Stringfellow discloses ceramic compositions useful as arc extinguishing means in connection with circuit interrupting equipment. The compositions comprise a substantial quantity of cordierite crystals, specifically more than 50% of such crystals, having a specific ultimate composition which can be defined on an MgO-SiO 2 -Al 2 O 3 phase diagram as 5 to 15% MgO, 22 to 58% Al 2 O 3 and 38 to 63% SiO 2 .
U.S. Pat. No. 3,040,213 to Byer et al. discloses composite "glaceramic" bodies useful in the fabrication of electrical components such as printed circuits which can be integrally united or interfused to produce a monolithic structure from separate preformed bodies.
U.S. Pat. No. 3,246,972 to Smith et al. discloses that cordierite has been commonly resorted to for the formation of compositions having high thermal shock resistance, high temperature and chemical durability and low thermal expansion but that it suffers from the problem that its expansion coefficient is high enough to limit the thermal shock that articles made therefrom can withstand and to cause excessive warpage of such articles.
U.S. Pat. No. 3,824,196 to Benbow et al. discloses that cordierite has been utilized in catalyst supports.
U.S. Pat. No. 3,885,977 to Lachman discloses an extruded, honeycombed monolithic fired ceramic whose primary crystal phase is cordierite and whose microstructure is characterized by a greater than random orientation of anisotropic cordierite crystallites. The product is particularly adapted for use as a catalytic support matrix for emission control.
U.S. Pat. No. 3,954,672 to Somers et al. discloses cordierite refractory compositions suitable for making a catalyst substrate as well as other ceramic bodies. Somers et al. discloses the firing of green, dried monoliths in air at a temperature of at least 2,550° F. to enable the formation of the maximum amount of cordierite phase.
U.S. Pat. No. 3,993,821 to Goss discloses the use of molybdenum as a metallization for application to green, unfired beryllia ceramics in single or multilayer laminates.
U.S. Pat. No. 4,109,377 to Blazick et al. discloses a method for manufacturing a multilayer ceramic which is particularly suitable for carrying semiconductor chips wherein a particulate mixture containing a metal and the metal's oxide in a ratio of between 1:1 to 9:1 is deposited in a pattern on at least a portion of a plurality of ceramic layers, the patterns are then dried and laminated under substantial pressure and fired at an elevated temperature. The metal oxide allows shrinkage of the metallization so that it more nearly matches that of the ceramic. Preferred metals and metal oxides include molybdenum powder and molybdenum trioxide powder.
U.S. Pat. No. 4,153,491 to Swiss discloses a green ceramic sheet adaptable for accelerated sintering comprising a high alumina ceramic green sheet having an average particle size greater than 1 micron.
U.S. Pat. No. 4,234,367 to Herron et al. discloses the formation of sintered glass-ceramic substrates containing multilevel interconnected thick-film circuit patterns of copper-based conductors obtained by firing in a controlled ambient of hydrogen and H 2 O at temperatures below the melting point of copper.
U.S. Pat. No. 4,301,324 to Kumar et al. discloses sintered glass-ceramic substrates containing multilevel, interconnected thick-film circuit patterns of highly conductive metals which can be fired in air or in neutral atmospheres at temperatures below the melting point of the metals. The invention is based upon the discovery that finely divided powders of certain glasses sinter to essentially zero porosity at temperatures below 1,000° C.
Japanese Patent Application No. 53-71269 discloses a multilayer circuit substrate produced by preparing an unfired multilayer ceramic substrate comprising conductor circuit layers each having, as an electroconductive material, a high melting metal powder which can be molybdenum plated with a noble metal.
Japanese Patent Application No. 55-42516 discloses a ceramic circuit board including buried conductor layers and surface conductor layers where the surface conductor layers can be made of molybdenum and include a copper or nickel-copper plated layer.
SUMMARY OF THE INVENTION
It has been found that in the formation of fired dielectric substrates improved product characteristics are obtained if the substrate comprises crystalline cordierite particles.
A method of forming such a dielectric substrate comprises admixing the crystalline cordierite particles with a binder and solvent therefor, casting the mixture into a sheet, drying the cast sheet to form a self-supporting green sheet and then heating the green sheet (herein often a "green ceramic sheet") to burn out the binder and sinter the crystalline cordierite particles together.
One object of this invention is to provide novel dielectric substrates based upon cordierite.
A further object of the invention is to provide a method of making novel dielectric substrates with a high cordierite content which comprises a co-sintered ceramic-metal structure wherein the metal is molybdenum-based.
Another object of the present invention is to provide multilayer ceramic substrates which are compatible with a metallization pattern thereon, most preferably a molybdenum metallization pattern, and co-fireable therewith.
Yet another object of this invention is to provide a method for fabricating multilayer ceramic substrates containing an internal pattern of metallization or conductors, which can be refractory metals or other suitable metals, most preferably of molybdenum.
Still another object of this invention is the fabrication of multilayer ceramic substrate carriers for semiconductor component chips in which conductors, most preferably molybdenum conductors for attachment of chips, are provided at various levels within the substrate carrier.
DESCRIPTION OF PREFERRED EMBODIMENTS
The crystalline cordierite per the present invention can be the naturally occurring magnesium-aluminum-silicate mineral having the theoretical formula 2MgO.2Al 2 O 3 .5SiO 2 corresponding to a composition of 13.8% MgO, 34.9% Al 2 O 3 and 51.3% SiO 2 .
Synthetic crystalline cordierite products are also useful which are produced by calcining mixtures of talc and clay or other aluminum silicates.
Cordierite is particularly useful per the present invention because of its low coefficient of thermal expansion, its ability to withstand thermal shock and its low dielectric constant.
The crystalline cordierite used in the present invention has a coefficient of thermal expansion of about 15×10 -7 ° C. -1 measured from 20° to 100° C., when sintered in the range of about 1350° to about 1450° C.
The size of the cordierite per the present invention is not overly important and is selected from those sizes as are conventionally used in the art to form fireable ceramic green sheets. Typically, this is on the order of from about 0.1 to about 10 microns, and this size range can be adjusted by conventional procedures such as ball or vibro-milling, if desired or necessary, to reduce particle size.
It is most preferred that the low dielectric constant substrates of the present invention have a dielectric constant less than about 6.
The Polymeric Binder
As is well known in the art, green ceramic substrates are formed of a particulate ceramic material in combination with a polymeric binder.
With multilayer ceramic materials, there is a subtle interaction between the dielectric constant of the ceramic and the electrical conductivity of the conductor or metallization pattern used. As a general rule, a lower dielectric constant and a higher conductivity for the ceramic substrate and metallization pattern, respectively, are beneficial to the performance of an MLC.
The polymeric binder used in the present invention can be freely selected from those polymeric binders used in the prior art.
In general, these are long chain thermoplastic polymers that are soluble in standard organic solvents such as lower aliphatic alcohols, e.g., methanol, ketones, e.g., acetone, methylisobutylketone (MIBK), etc. A preferred polymeric binder is polyvinyl butyral, e.g., Butvar B-98, available from Monsanto Co., which is approximately 80 mole % polyvinyl acetal, 18-20 mole % polyvinyl alcohol and 0-2.5 mole % polyvinyl acetate. Of course, as one skilled in the art will appreciate, other polymeric binders as are known in the art can be used, e.g., polyvinyl acetate, polymethylmethacrylate, polyvinyl formal, etc. Typically, the polymeric binder is used in combination with a plasticiser for flexibility purposes, e.g., dioctyl phthalate, dibutyl phthalate, dipropylene glycol dibenzoate, etc. While not limitative, weight ratios of polymeric binder to plasticizer of about 10:1 to about 4:1 are typical.
The molecular weight of the polymeric binder is not important per the present invention and can be freely selected from molecular weights as are used in the prior art. As one skilled in the art will appreciate, it is only necessary that the polymeric binder permit easy formation of the slurry which is used to form the green ceramic substrate, provide sufficient strength so that the green sheet may be appropriately handled during processing, and be easily volatilized during sintering to permit clean removal thereof during formation of the fired ceramic substrate.
Optional Ingredients
In the formation of green ceramic sheets, the only essential ingredients are a particulate ceramic material and a polymeric binder illustrating the characteristics as above.
However, conventional additives as are well known in the art can be used, and generally will be used, in combination therewith, for example, materials from the system MgO-Al 2 O 3 -SiO 2 , particularly Al 2 O 3 , MgAl 2 O 4 and/or crystalline or amorphous aluminosilicates. The purpose of the additive is to enhance mechanical and thermal properties as well as to modify in a favorable fashion sintering behavior. Of particular use is the addition of small amounts of an amorphous aluminosilicate composition comprising MgO, CaO, Al 2 O 3 and SiO 2 . These amorphous materials assist the sintering operation such that dense structures can be realized.
The proportion of such additives is not overly important, but typically will be on the order of about 1 to about 15 weight percent based on the weight of the ceramic.
Solvent
The slurry which is utilized to form the green ceramic sheet per the present invention is typically formed using a solvent. The nature of the solvent is not important and is selected from those as are conventionally used in the art. Typically solvents include methanol, toluene, ketones such as acetone, MIBK, methylethylketone, etc., preferably a mixture of methanol and MIBK, e.g., a mixture of methanol and MIBK at a 1:3 weight ratio.
Slurry Proportions
The slurry which is utilized to form the green ceramic sheet of the present invention contains proportions of the desired components as are conventional in the art.
While by no means limitative, typically this will result in an inorganic to organic weight ratio of about 1.5 to 2:1 parts inorganics per 1 part of organics. Of this, the cordierite parts will comprise 85 to 100 weight % of the inorganics, remainder the optional ingredients previously described. The organic portion will comprise 10 to 20 parts by weight of polymeric binder and plasticizer with the remainder being the chosen solvent(s).
Slurry/Green Ceramic Sheet Formation
The slurry and the green ceramic sheet per the present invention are formed following conventional prior art procedures. Reference should be made to the Kaiser et al. article earlier incorporated by reference for disclosure regarding such.
Typically, however, the cordierite and other optional ingredients are weighed out in the proper proportion, particle size is adjusted if desired or necessary, the constituents of the organic binder such as the desired thermoplastic resin, a plasticizer and the solvent(s) are separately blended and then the ceramic phase and the organic phase are weighed out and blended in a ball mill, and the resulting slurry (often called a slip) is cast into tape form by doctor blading onto a web of Mylar®, the blade spreading the slurry into a uniform film. After the slurry is spread out on the Mylar® web, it is typically allowed to remain until enough of the solvent has evaporated so that the slurry will not flow when moved. The thus partially dried slurry is allowed to completely dry and is then removed from Mylar® backing and is ready for use in subsequent operations.
Since typically the green ceramic sheet at this time is rather large in size, usually working blanks are cut from the green ceramic sheet and via holes are selectively punched in a standard grid pattern in the thus formed working blank.
At this stage, if desired, circuit metallization can be formed on the green sheet working blank by silk screening in a conventional manner using a conventional metal paste, e.g., of molybdenum, tungsten or copper metal powders in a conventional organic binder system.
Typically the metal has a particle size on the order of from about 0.5 to about 5.0 microns, though this is not limitative.
If a solvent is used to form the metallization paste, it should be one which is driven off at or below the firing or sintering temperature of the cordierite being used so that only the residual metallization remains after the process is completed.
The via holes are filled in a conventional manner typically by a one-pass screen simultaneously with circuit pattern screening in a conventional manner. Alternatively, two silk screening operations can be used to fill the via holes, one from the bottom using a metal paste followed by one from the top to fill in the holes, and the circuit pattern can be screened simultaneously or subsequently to the via hole filling. This procedure is also conventional.
After the above procedure, typically a stack of green ceramic blanks will be formed which will become the final module.
Generally, a set of working blanks is stacked over registration pins in the proper sequence, the stack is placed in a laminating press and moderate heat and pressure applied, e.g., typically from about 2,000 to about 5,000 psi and about 70° to about 90° C. for about 2 to about 10 minutes, whereupon the thermoplastic binder in the green sheet blank softens and the layers fuse together, deforming around the metallization pattern to completely enclose the lines.
Following the above procedure, the "green module" is fired, typically at about 1300° to about 1450° C. for about 1 to about 5 hours in an atmosphere such as wet hydrogen having a dew point of 30° to 60° C. The purpose of firing is to drive off the binder and to sinter the ceramic and metal particulates together into a ceramic dielectric structure having the desired pattern of electrical conductors extending internally therein.
The module is now ready for various post-sintering operations which are conventional in the art and which are disclosed in detail in the Kaiser et al. article earlier incorporated by reference.
Sintering of the metallization can be appreciably accelerated by reducing the dew point of the sintering atmosphere and/or the particle size of the starting powder. Accordingly, the sintering of, e.g., molybdenum, can be conducted at a temperature on the order of 1,400° C., which is the approximate sintering range of the cordierite-based ceramic systems of the present invention.
It should be understood, of course, that the present invention is not limited to molybdenum as the metallization, and other metals as earlier exemplified can be used with success, the sintering temperature and time being appropriately modified in a manner which will be apparent to one skilled in the art.
Having thus generally described the invention, the following working example is offered to illustrate the same.
EXAMPLE
In this example, the final MLC comprised 12 layers, each layer being 20 mm thick and having the following dimensions: 185 mm×185 mm. The cordierite composition used had the following composition: 90 wt.% crystalline cordierite and 10 wt.% amorphous aluminosilicate (MgO, CaO, Al 2 O 3 and SiO 2 ). The average particle size thereof was 4 microns.
The binder selected was polyvinyl butyral (Butvar B-98 from Monsanto) with about 20 wt.% dipropylene glycol dibenzoate based on the PVB weight.
The solvent selected was a mixture of methanol and MIBK (1:3 parts by weight).
The cordierite composition, binder and solvent at proportions of 64 weight %, 6 weight % and 30 weight %, respectively, based on slurry weight, were then milled in a conventional fashion.
A green sheet having a thickness of 20 mm was produced from the slurry obtained using a conventional doctor blading method.
The green sheet was then dried in air for 24 hours, whereafter the same was cut into working blanks having the following dimensions: 185 mm×185 mm and registration holes were punched therein in a conventional manner.
Thereafter, via holes having a diameter of 150 microns were selectively punched on a standard grid pattern in each working blank.
Following the above procedure, the via holes were filled from the bottom and then the top in a conventional manner using a molybdenum metallization paste (85 wt.% solids, balance conventional polymeric binder and solvent).
Thereafter, a wiring pattern was formed by printing the above molybdenum metallization paste on each working blank in a conventional manner, forming the desired metallization pattern on the working blanks.
Following the above procedure, 12 of the above blanks were stacked and laminated together at a temperature of 75° C. and a pressure of 4,000 psi for 5 minutes.
Thereafter, the MLC intermediate was sintered (fired) in a reducing atmosphere, specifically, a water/hydrogen atmosphere having a dew point of 40° C. at 1430° C. for 120 minutes.
Following the above, the essential inventive processing steps of the present invention have been completed and, thereafter, the fired MLC may be subjected to various post-sintering operations as disclosed in the Kaiser et al. publication earlier incorporated by reference.
All of these post-sintering operations are conventional in the art and these operations will be obvious to one skilled in the art.
While there have been described what are at present considered to be the preferred embodiments of this invention, it will be obvious to those skilled in the art that various changes and modifications can be made therein without departing from the invention, and it is, therefore, intended to cover all such changes and modifications as fall within the true spirit and scope of the invention. | 4y
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BACKGROUND
This disclosure relates to systems and techniques for the creation and use of a thesaurus for identifiers of complex data assemblies.
A data assembly is a collection of associated information that is treated as an entity in data processing activities. Data assemblies include complex data structures, as well as abstractions such as data objects that can include information drawn from one or more complex data structures. Hereinafter, for the sake of convenience, the term “complex data structures” includes such abstractions even though the abstractions themselves need not be a single complex data structure.
Complex data structure types, also referred to as “composite data types” and “data types,” are assemblies of simple data types. Simple data types, also referred to as “primitive” and “elementary” data types, cannot be broken down into smaller component data types. In general, simple data types are the basic data types that are predefined in a language for authoring machine-readable instructions. Simple data types include, e.g., character, numeric, string, and Boolean data types. Simple types do not have element content and do not carry attributes.
In addition to simple data types, complex data structure types can also include other complex data structures in the assembly. In general, complex data structure types are defined by a user to fit the operational context of a particular set of machine-readable instructions. Example complex data structure types include data objects, records, arrays, tables, and the like. Complex data structure types can be defined by a user who assembles a set of elements, fields, and/or attributes to form a reusable data structure. Each of these has a type and, as discussed above, hierarchical and recursive complex data structure types that are themselves assembled from complex data structure types can be formed.
A data structure identifier, or a “key,” is information that identifies a complex data structure for data processing activities performed in accordance with a set of machine-readable instructions. The identification is generally unambiguous, i.e., each identifier or key generally refers to a single complex data structure to the exclusion of all other data structures.
A data structure identifier can include, e.g., a name or a value that identifies the object within an identification scheme, a scheme identifier that identifies a frame of reference in which it is possible to identify a data structure, and an agency identifier that identifies the entity that defines the identification scheme and issues names for data structures within the identification scheme.
Different applications, different modules, different data processing systems, different data processing system landscapes, and different public identification scheme entities (such as Dun & Bradstreet, which issues DUNS numbers, and GS1, which issues GTIN's) can use different identification schemes, in which even the same single data structure is referred to using different identifiers.
Moreover, even a single application, module, data processing system, data processing system landscape, and/or public identification scheme entity can use multiple complex data structures of the same semantic type to refer to the same real-world item. Semantic type is a descriptive attribute of information that identifies the behavior (i.e., the semantics) for that information. The semantic type of information can identify the usage and rules for that information to set of a data processing instructions. Two or more objects (or other complex data structures) of the same semantic type can be used to refer to the same single real world entity in one or more sets of data processing activities. For example, a data processing module can include a “product object” instance that includes attributes and values that characterize an instance of a real-world item as a product. The same data processing module can include a “material object” that has the same attributes and values and characterizes the same real-world item, but as a material. Moreover, a second data processing module can include a “design object” that has the same attributes and values and characterizes the same real-world item, but as a design. Even though such objects may refer to the same single real-world entity and share the same semantic type, the various objects may be referred to using different identifiers.
When information regarding a data structure or structures is exchanged, a process called key mapping can be used to translate the different identifiers. In general, key mapping involves accessing a key mapping database where keys used by a first set of processing activities are associated with keys used by a second set of processing activities. When information regarding one or more complex data structures is exchanged, one of the sets of processing activities can access the key mapping database to translate the key from the source processing activities to the key in the second processing activities.
SUMMARY
Systems and techniques for the creation and use of a complex data structure identifier thesaurus are described.
In one aspect, an article comprises one or more machine-readable media storing instructions operable to cause one or more machines to perform operations. The operations include receiving, from a data processing system, a collection of mapping information identifying a first object and a first collection of two or more keys used to identify the first object, determining whether a first key in the first collection is found in a first mapping group of a mapping data store, determining whether second key in the first collection is found in a second mapping group of the mapping data store, and merging the first mapping group and the second mapping group to reflect that objects from the first mapping group and the second mapping group are related.
This and other aspects can include one or more of the following features. Each mapping group can include references to two or more related objects. A first of the related objects can be associated with a first collection of one or more keys and a second of the related objects can be associated with a second collection one or more keys. Also, none of the keys in the first collection need be found in the second collection and none of the keys in the second collection need be found in the first collection. The first mapping group and the second mapping group can be merged by forming a merged mapping group.
The first mapping group and the second mapping group can also be merge by eliminating a reference to a first object found in one of the first mapping group and the second mapping group, and associating keys that were associated with the eliminated first object with an object in the merged mapping group. The merging of the first mapping group and the second mapping group can also include storing, outside of any mapping group, at least one of a reference to the first object or a reference an object from one of the first mapping group and the second mapping group.
The operations can also include receiving, from a second data processing system, a second collection of mapping information that identifies a second object and a second collection of two or more keys used to identify the second object, determining that the second object is related to the object reference stored outside of any mapping group, and creating a new mapping group that includes the second object and the object reference that was stored outside of any mapping group. The operations can also include adding a key from the first collection to a collection of keys in the mapping data store and/or mapping keys using the mapping data store. Keys can be mapped by mapping keys associated with multiple objects in the same mapping group to each other and/or by mapping keys associated with a single object.
In another aspect, an article includes one or more machine-readable media storing instructions operable to cause one or more machines to perform operations. The operations can include receiving, from a data processing system, a collection of mapping information that identifies a first object and a first collection of two or more keys used to identify the first object, determining that none of the keys in the first collection are found in any mapping group of a mapping data store and that the first object is not related to any object found in any mapping group of the mapping data store, determining that a related object that is associated with a second collection of keys exists outside of any mapping group of the mapping data store, wherein the related object is related to the first object in that the related object includes same attributes as the first object and wherein none of the keys in the first collection are found in the second collection and none of the keys in the second collection are found in the first collection, and creating a new mapping group to include the related object and the first object.
This and other aspects can include one or more of the following features. The new mapping group can be created by adding the related object in association with the keys in the second collection to the new mapping group. The operations can also include receiving a second collection of mapping information that identifies the first object and a third collection of two or more keys and associating the first key with the first object in the new mapping group. This can be done when a first key in the third collection can be different from any of the keys in the first collection. The operations can also include receiving a second collection of mapping information that identifies an object and a third collection of two or more keys and eliminating the new mapping group. This can be done when one of the keys in the third collection can be found in the first collection and another of the keys in the third collection can be found in the second collection.
The new mapping group can be eliminated by storing a reference to at least one of the object, the first object, and the related object outside any mapping group in the data store. The operations can also include receiving a second collection of mapping information that identifies an object and a third collection of two or more keys and merging the new mapping group and the second mapping group. This can be done when one of the keys in the third collection can be found in the first collection and another of the keys in the third collection can be found in a second mapping group of the mapping data store. Keys can also be mapped using the mapping data store. For example, keys associated with multiple objects in the same mapping group can be mapped to each other. The mapping data store can include keys stored as core component type identifiers.
In another aspect, a memory for storing data for access by operations performed by one or more data processing systems can include mapping data store. The mapping data store can include a mapping group including references to two or more related objects in different data processing systems using different identification schemes and a reference to an object outside of any mapping group. A first of the related objects can be associated with a first collection of one or more keys and a second of the related objects being associated with a second collection one or more keys. None of the keys in the first collection need be found in the second collection and none of the keys in the second collection need be found in the first collection. The object outside of any mapping group can be associated with a third collection one or more keys. None of the keys in the third collection need be found in the first collection or the second collection and none of the keys in the first collection or the second collection need be found in the third collection. The object outside of any mapping group need not be related to any object in any mapping group. Related objects can be related in that they include same attributes.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic representation of an example complex data structure, namely a data object.
FIGS. 2 and 3 are schematic diagrams of example data processing system landscapes.
FIGS. 4A and 4B is a schematic representation of how related data objects can be identified using different identifiers.
FIG. 5 is a schematic representation of a mapping data store for an object thesaurus.
FIG. 6 is a flowchart of a process for the creation and use of a data store of an object thesaurus.
FIG. 7 is a flowchart of a process for the creation of a data store of an object thesaurus.
FIGS. 8-13 schematically illustrate various examples of the modification of the mapping data store of FIG. 5 based on mapping information.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
FIG. 1 is a schematic representation of an example complex data structure, namely a data object 100 . Data object 100 includes an object class name 105 , a collection of attributes 110 , and a collection of operations 115 . A data object such as data object 100 is a complex data structure that generally assembles information to represent a concrete or abstract real-world entity. An object can be of a certain object class, with individual objects being instances of that class. The entities represented by an object can include, e.g., a set of data processing instructions (such as a program), a data structure (such as a table), individual entries in a data structure (such as a record in a table), a data processing system, a customer, a product, a time, or a location. A data object is generally free of internal references and information stored in a data object can be changed without concomitant changes to the data processing instructions that handle the data object. In some implementations, the information in a data object can be stored in a contiguous block of computer memory of a specific size at a specific location, although this is not necessarily the case.
Object class name 105 is the name of the class of data object 100 . For example, data object 100 is of the “SalesOrder” class and represents a sales order entity. Attribute collection 110 includes attributes that are properties of data object 100 and have associated values that characterize the entity represented by data object 100 . In particular, the attributes in collection 110 are HeaderID, CustomerID, SalespersonID, Date, Tax, and SalesGroupID. These attributes have values characterizing the sales order represented by data object 100 .
Operation collection 115 includes various data processing activities that can be performed on data object 100 . The operations in collection 115 can, e.g., return a value or change a value of an attribute in collection 110 , in another data object, or the like. The operations in collection 115 can also cause the creation and deletion of objects.
FIG. 2 is a schematic representation of a distributed data processing system landscape 200 . A distributed data processing system landscape can include a collection of data processing devices, software, and/or systems (hereinafter “data processing systems”) that operate autonomously yet coordinate their operations across data communication links in a network and on individual data processing devices. By operating autonomously, the data processing systems can operate in parallel, handling local workloads of data processing activities. The data communication links allow information regarding the activities, including the results of performance of the activities, to be exchanged between data processing systems. To these ends, many distributed data processing systems include distributed databases and system-wide rules for the exchange of data.
System landscape 200 thus is a collection of data processing systems that exchange information for the performance of one or more data processing activities in accordance with the logic of one or more sets of machine readable instructions. System landscape 200 includes one or more servers 205 that are in communication with a collection of clients 210 , 215 , 220 over a collection of data links 225 .
Server 205 is a data processing system that provides services to clients 210 , 215 , 120 . The services can include, e.g., the provision of data, the provision of instructions for processing data, and/or the results of data processing activities. The services can be provided in response to requests from clients 210 , 215 , 220 .
The services can be provided by server 205 in accordance with the logic of one or more applications 230 , 235 . An application is a program or group of programs that perform one or more sets of data processing activities. An application can perform data processing activities directly for a user or for another application. Examples of applications include word processors, database programs, Web browsers, development tools, drawing, paint, image editing programs, and communication programs. In the context of enterprise software that is operable to integrate and manage the operations of a company or other enterprise, applications can be allocated to managing product lifecycles, managing customer relationships, managing supply chains, managing master data, managing financial activities, and the like.
Clients 210 , 215 , 220 are data processing systems that receive services from server 205 . Clients 210 , 215 , 220 can be responsible for other data processing activities, such as managing interaction with human users at their respective locations. For example, client 220 can perform data processing activities in accordance with the logic of an application 240 , and client 215 can perform data processing activities in accordance with the logic of an application 245 . In these course of these and other data processing activities, clients 110 , 115 , 120 can generate requests for such services and convey the requests to server 205 over one or more of data links 225 .
Data links 225 can form a data communication network such as a LAN, a WAN, or the Internet. System landscape 200 can also include additional data links, including direct links between clients 210 , 215 , 220 and data links to systems and devices outside landscape 200 , such as a communications gateway (not shown). Additional data processing activities, performed in accordance with the logic of additional applications, can be performed at the systems and devices outside landscape 200 .
The roles of “server” and “client” can be played by the same individual data processing system in system landscape 200 . For example, the data processing system denoted as server 205 may receive certain services from one of clients 210 , 215 , 220 . Thus, a data processing system may be a “server” in the context of a first set of services but a “client” in the context of a second set of services.
FIG. 3 is a schematic representation of another implementation of a system landscape, namely, a system landscape 300 . System landscape 300 is a three tiered hierarchy of data processing systems and includes application servers 305 , 310 , 315 , one or more database servers 320 , and presentation systems 325 , 330 , 335 . Application servers 305 , 310 , 315 and database server 320 are in data communication with each other and with presentation systems 325 , 330 , 335 over a collection of data links 340 .
Application servers 305 , 310 , 315 are data processing systems that provide services to presentation systems 325 , 330 , 335 and/or database server 310 . Each application server 305 , 310 , 315 can provide services in accordance with the logic of one or more applications. Moreover, individual application servers can also provide services in accordance with the logic of multiple applications, and services in accordance with the logic of a single application can be provided by multiple application servers. In the illustrated implementation, application server 305 provides services in accordance with the logic of applications 345 , 350 . Application server 310 provides services in accordance with the logic of application 355 . Application server 315 provides services in accordance with the logic of application 360 .
Database server 320 is a data processing system that provides storage, organization, retrieval, and presentation of instructions and data services to application servers 305 , 310 , 315 and/or presentation systems 325 , 330 , 335 .
Presentation systems 325 , 330 , 335 are data processing systems that receive services from application servers 305 , 310 , 315 and database server 320 and perform other data processing activities. For example, presentation systems 325 , 330 , 335 can manage interaction with human users at their respective locations, such as the display of information on a graphical user interface.
In the illustrated implementation, presentation system 325 performs data processing activities in accordance with the logic of an application 365 , and presentation system 335 performs data processing activities in accordance with the logic of an application 370 . In the course of these and other data processing activities, presentation systems 325 , 330 , 335 can generate requests for services and convey the requests to application servers 305 , 310 , 215 and database server 320 over one or more of data links 340 .
FIG. 4A is a schematic representation of how data object 100 ( FIG. 1 ) can be identified during different data processing activities using different identifiers. In particular, data processing activities performed in accordance with the logic of applications 405 , 410 , 415 , 420 all identify data object 100 during various identifications, represented by arrows 425 , 430 , 435 , 440 . However, the activities of applications 405 , 410 , 415 , 420 use different identifiers to uniquely identify data object 100 . In particular, identification 425 uses keys k 1 and k 2 . Identification 430 uses keys k 3 and k 4 . Identification 435 uses keys k 5 and k 6 . Identification 440 uses keys k 7 and k 8 .
The existence of multiple unique keys k 1 , k 2 , k 3 , k 4 , k 5 , k 6 , k 7 , k 8 for the same data object can arise for any of a number of different reasons. For example, some of keys k 1 , k 2 , k 3 , k 4 , k 5 , k 6 , k 7 , k 8 can be universally unique ID's (UUID's) that are used internally by data processing activities. Moreover, different UUID's can be assigned by different agents for different identification schemes. Further, some of keys k 1 , k 2 , k 3 , k 4 , k 5 , k 6 , k 7 , k 8 can be identifiers that are tailored for use by humans. For example, a human user may use a value of an attribute of a data object to uniquely identify the object. For example, a human user may use a key such as “BMW” or “Toyota” to uniquely identify a customer object. Moreover, different human users and different public identification scheme entities may use different identifiers to uniquely identify a data object.
FIG. 4B is a schematic representation of how multiple data objects 445 , 450 , 455 that describe the same real-world entity can be identified using different identifiers. In particular, data processing activities performed in accordance with the logic of application 405 can identify customer object 445 using keys k 1 and k 2 . Data processing activities performed in accordance with the logic of application 405 can identify business partner object 450 using keys k 3 and k 4 . Data processing activities performed in accordance with the logic of application 410 can identify salesperson object 455 using keys k 5 and k 6 . A single real-world entity is described by data objects 445 , 450 , 455 and data objects 445 , 450 , 455 can be of the same semantic type.
FIG. 5 is a schematic representation of a mapping data store 500 of an object thesaurus. Mapping data store 500 is a collection of key mapping information that associates the various keys used to identify one or more data objects in one or more data processing systems. For example, the different data processing systems can operate using different identifiers that are issued for different identification schemes by different entities. Moreover, mapping data store 500 can act as a centralized repository for key mapping information from the different data processing systems. For example, the data processing systems whose mapping information is stored at mapping data store 500 need not maintain separate key mapping information. Thus, in some implementations, mapping data store 500 can be a reusable component that provides a consistent view of mapping information to other components. In particular, details regarding data processing instructions associated with mapping data store 500 such as data replication and mapping group merges (as discussed further below) can be hidden from calling components.
Mapping data store 500 can be a structured data collection, such as a table, a record, a data object, a list, or the like. The key mapping information in mapping data store 500 can also be subdivided. For example, key mapping information in mapping data store 500 can be divided and the resulting divisions stored in different data structures. Mapping data store 500 can be stored at a variety of locations in a data processing system landscape. For example, mapping data store 500 can be stored at one or more of server 205 and clients 210 , 215 , 220 in system landscape 200 ( FIG. 2 ). As another example, mapping data store 500 can be stored at one or more of database server 320 , application servers 305 , 310 , 315 , and presentations systems 325 , 330 , 335 in system landscape 300 ( FIG. 4 ). Mapping data store 500 can also be stored remotely from system landscapes 200 , 300 and yet be accessed from system landscapes 200 , 300 . In some implementations, the storage of a single mapping data store 500 can be distributed across different systems in a system landscape. Mapping data store 500 can be structured into a file, packed, compressed, or otherwise prepared for storage. Mapping data store 500 can also include metadata or executable instructions that are relevant to accessing key mapping information. Examples of metadata include default keys, leading keys, and internal keys. Such metadata can be used internally, i.e., for data processing activities associated with mapping data store 500 , and need not be provided to user interfaces.
Mapping data store 500 includes mapping groups 505 , 510 . A mapping group is a collection of references to related objects. The way in which the objects are related can be defined, e.g., by a user or by a set of data processing activity that accesses mapping data store 500 . For example, a user can define a mapping group to include references to the same objects that are involved in different sets of data processing activities that use different identification schemes. The objects in such a mapping group can be identical in that they have the same attributes and values, but are subject to different operations in different data processing systems. As another example, a component set of data processing activities can group similar objects in a mapping group. The objects can be similar in that there is a logical relationship between the objects. Such a logical relationship can be specified, e.g., by the component set of data processing activities in accordance with the logic of those data processing activities. One example of such a logical relationship is that the object describe the same real-world entity.
Mapping group 505 includes references to objects 515 , 520 , 525 . Mapping group 510 includes references to objects 530 , 535 . Each of objects 515 , 520 , 525 , 530 , 535 is associated with one or more keys that are used to uniquely identify objects 515 , 520 , 525 , 530 , 535 for the relevant data processing activities. For example, object 515 can be identified using keys 540 , 545 during data processing activities performed in accordance with a first set of instructions. Object 520 can be identified using keys 550 , 555 during data processing activities performed in accordance with a second set of instructions. Object 525 can be identified using keys 560 , 565 during data processing activities performed in accordance with a third set of instructions. Object 530 can be identified using keys 570 , 575 during data processing activities performed in accordance with the first set of instructions. Object 535 can be identified using keys 580 , 585 , 590 during data processing activities performed in accordance with a fourth set of instructions. As shown, the number of keys per object is arbitrary. Moreover, the number of objects in excess of one in each mapping group is arbitrary.
In one implementation, mapping data store 500 is implemented as a storage of a collection of core component type (CCT) identifiers. A core component type identifier can identify a particular business object along with the context in which that identification is valid. For example, in addition to the identifier of the particular object, a CCT identifier can identify one or more of an identification scheme that assigned the identifier, the version of the identification scheme, an agent that administers that identification scheme, the identification scheme of such an agent, and the agent that administers the identification scheme of such an agent.
FIG. 6 is a flowchart of a process 600 for the creation and use of a mapping data store of an object thesaurus. Process 600 can be performed by one or more data processing systems that exchange information with one or more data processing systems. For example, one or more data processing systems can perform data processing activities for the creation of the data store for an object thesaurus, and one or more data processing systems can perform data processing activities for the use of the object thesaurus.
The system(s) performing process 600 can assemble key mapping information from three or more data processing systems into a single mapping data store at 605 . Such an assembly of key mapping information is more complicated than assembling mapping information from two or fewer data processing systems. For example, as discussed further below, the number and type of mappings is more difficult to define with larger numbers of data processing systems. As another example, increased numbers and different categories of mergers and deletions may be required.
The system(s) performing process 600 can also map the keys using the mapping data store at 610 . For example, keys can be mapped between two or more data processing systems using different identification schemes, or keys can be mapped between synchronized systems. The mappings can be performed, e.g., in response to requests received from the data processing systems themselves.
FIG. 7 is a flowchart of a process 700 for the creation of a data store for an object thesaurus. Process 700 can be performed independently or in conjunction with other data processing activities. For example, process 700 can be performed at 605 in process 600 ( FIG. 6 ).
The system(s) performing process 700 can receive information that identifies a data object and one or more keys for identifying the data object in another data processing system at 705 . The information that identifies a data object can itself be a key for identifying the data object. In some implementations, the information can be received directly from the data processing system that uses those keys. For example, the information can be received in a message that includes the keys as CCT identifiers.
The system(s) performing process 700 can determine if the received information appears in one or more existing mapping groups in the data store at 710 . The received information appears in an existing mapping group when the object or the keys identified in the information appear in an existing mapping group. The determination can be made by comparing the received information to the contents of the data store. For example, received keys can be compared to existing keys.
If the system(s) performing process 700 determines that the received information does appear in an existing mapping group, then the system(s) can, as appropriate, modify the data store at 715 . If the received information is already found in the data store and the data store already accurately reflects the received information, no modifications are necessarily performed. However, if modifications are appropriate, they can include adding some or all of the information to the data store, deleting information from the data store, and/or changing the associations between mapping groups, objects, and keys in the data store. For example, new references to new objects can be added, new keys can be added to existing objects, new mapping groups can be created, and/or existing mapping groups can be merged. Illustrative modifications are discussed further below.
If the system(s) performing process 700 determines that the received information does not appear in an existing mapping group, then the system(s) can determine if there is an object outside of existing mapping groups that has matching keys at 720 . The determination can be made by comparing the received information to the contents of the data store that are outside of mapping groups.
If the system(s) performing process 700 determines that there are not any related objects outside of existing mapping groups with different keys, then the system(s) can add the information to a data store outside of any mapping group at 725 . The addition can occur in a number of ways. For example, if a related object is found, but with at least some identical keys, any keys from the received information that do not appear in the related object outside of the existing mapping group can be added to the related object outside of the existing mapping group. As another example, if no related object is found, the received object and its keys can be added to the data store outside of any mapping group. In one implementation, this is done by inserting key, object, and group information into the relevant tables of the database.
If the system(s) performing process 700 determines that there are related objects outside of existing mapping groups that have different keys, then the system(s) can create and populate a new mapping group at 730 . The new mapping group can be populated with the received information, as well as the related object and its associated keys that were found in the data store but outside of existing mapping groups. Once the new mapping group is populated, the related object outside of existing mapping groups can be deleted from the data store.
After the activities of any of 715 , 725 , or 730 , the system(s) performing process 700 can return to receive additional information that identifies a data object and one or more keys for identifying the data object in another data processing system at 705 . Through such repetitions, a data store can be assembled and updated to reflect the current state of two or more data processing systems. Further, the data store can be made available during such repetitions for mapping the keys between systems.
FIGS. 8-13 schematically illustrate various examples of the modification of mapping data store 500 based on mapping information. The illustrated additions, modifications, and similar processes can be performed by one or more data processing systems at 715 in process 700 ( FIG. 7 ).
FIG. 8 is a schematic representation of information 800 that can be received by a system performing process 700 at 705 ( FIG. 7 ). Information 800 identifies an object 805 and keys 810 , 815 for identifying object 805 in a data processing system.
Keys 810 , 815 can be identified as identical to keys identified in one or more existing mapping groups in a data store. For example, key 810 can be identified as identical to key 575 in mapping group 510 in mapping data store 500 , and key 815 can be identified as identical to key 585 in mapping group 510 in mapping data store 500 .
FIG. 9 is a schematic representation of mapping store 500 after modification in light of information 800 ( FIG. 8 ). In particular, mapping group 510 and object 535 have been eliminated to reflect that objects 530 , 535 are mapped to each other. For example, the elimination of mapping group 510 and object 535 can reflect that objects 530 , 535 are related objects or even the same object. Also, object 530 has been associated with keys 580 , 585 , 590 and is now stored in mapping data store 500 outside of a mapping group. Although object 530 and keys 570 , 575 , 580 , 585 , 590 are not applicable to mapping between objects in different data processing systems since object 530 exists in a single system, the information embodied in object 530 and keys 570 , 575 , 580 , 585 , 590 is still useful. For example, object 530 and keys 570 , 575 , 580 , 585 , 590 can be used for key mapping within a single system or between synchronized systems. As another example, object 530 and keys 570 , 575 , 580 , 585 , 590 stand ready for the creation and population of a new mapping group when objects and keys from different data processing systems are received.
FIG. 10 is a schematic representation of information 1000 that can be received by a system performing process 700 at 705 ( FIG. 7 ). Information 1000 identifies an object 1005 and keys 1010 , 1015 , 1020 for identifying object 1005 in a data processing system.
Keys 1010 , 1015 , 1020 can be identified as identical to keys identified in one or more existing mapping groups in a data store. For example, key 1010 can be identified as identical to key 560 in mapping group 505 in mapping data store 500 , key 1015 can be identified as identical to key 570 in mapping group 510 in mapping data store 500 , and key 1020 can be identified as identical to key 575 in mapping group 510 in mapping data store 500 .
FIG. 11 is a schematic representation of mapping store 500 after modification in light of information 1000 ( FIG. 10 ). In particular, mapping group 510 and object 530 have been eliminated and object 535 has been added to mapping group 505 to reflect that objects 525 , 530 were not only related but also in the same data processing system. The addition of object 535 to mapping group 505 is also based on a prior identification of object 535 as related to object 530 . Also, object 525 has been associated with keys 560 , 565 , 570 , 575 .
FIG. 12 is a schematic representation of information 1200 that can be received by a system performing process 700 at 705 ( FIG. 7 ). Information 1200 identifies an object 1205 and keys 1210 , 1215 , 1220 , 1225 for identifying object 1205 in a data processing system.
Keys 1210 , 1215 , 1220 can be identified as identical to keys identified in an existing mapping group in a data store. For example, key 1210 can be identified as identical to key 550 in mapping group 505 in mapping data store 500 , key 1215 can be identified as identical to key 560 in mapping group 505 in mapping data store 500 , and key 1220 can be identified as identical to key 570 in mapping group 510 in mapping data store 500 . Key 1225 does not appear in mapping data store 500 before information 1200 is received.
FIG. 13 is a schematic representation of mapping data store 500 after modification in light of information 1200 and after addition of some of information 1200 ( FIG. 12 ). In particular, mapping group 510 and objects 525 , 530 have been eliminated and object 535 has been added to mapping group 505 to reflect that objects 520 , 525 , 530 were not only related but also in the same data processing system. The addition of object 535 to mapping group 505 is also based on a prior identification of object 535 as related to object 530 . Also, object 520 has been associated with keys 560 , 565 , 570 , 575 , and newly added key 1305 . Key 1305 has been newly added on the basis of its prior absence from mapping data store 500 .
Keys can be mapped using the mapping information stored in a mapping data store in a variety of different scenarios. For example, keys can be mapped when master data is distributed between harmonized data processing systems. Harmonized systems are systems which share at least one common identifier for data objects involved in data processing activities in those systems. Master data is information that is stored on a relatively long-term basis in one or more data processing systems and is often relevant to multiple processes in those systems. In the illustrative mapping data store 500 described above, keys to master data objects in such harmonized data processing systems will be associated with multiple objects in the same mapping group provided that the systems are synchronized as to those objects.
Keys can also be mapped when transactional data objects are distributed between harmonized data processing systems. Transactional data is information that records events occurring between individuals, groups, and organizations. Transactional data is generally created more frequently, and can be modified more often, than master data. In the illustrative mapping data store 500 described above, keys to transactional data objects in such harmonized data processing systems will be associated with multiple objects in the same mapping group provided that the systems are synchronized as to those objects.
Keys can also be mapped during synchronous access from one data processing system to another harmonized data processing system. Synchronous access can include a first data processing system reading of data directly from and writing data directly to a second data processing system. In the illustrative mapping data store 500 described above, keys for synchronous access in such harmonized data processing systems will be associated with multiple objects in the same mapping group provided that the systems are synchronized as to those objects.
Keys can also be mapped during translation of external identifiers. External identifiers are identifiers used by another data processing system landscape. For example, external identifiers can be included in messages and other information received from remote systems. In the illustrative mapping data store 500 described above, keys for the translation of external identifiers will be associated with the same single object, provided that the multiple identifiers of that single object have previously been identified to the mapping data store 500 as identifying the same object.
Keys can also be mapped during translation of incompatible sets of machine-readable instructions in the same data processing system landscape. Example incompatible sets of machine-readable instructions include unharmonized applications in the same data processing system landscape. In the illustrative mapping data store 500 described above, keys for translation between incompatible sets of machine-readable instructions will be associated with the same single object, provided that the multiple identifiers of that single object have previously been identified to the mapping data store 500 as identifying the same object.
A complex data structure thesaurus, such as data store 500 , can be also used in contexts outside of key mapping. For example, a complex data structure thesaurus can be used for object-based navigation. Object-based navigation is a navigation style based upon the characteristics at the object level, i.e., the contents of the objects and the relationship among the objects. With object-based navigation, users can specify a set of objects and their relationship. The system creates queries from the users' input and determines links dynamically based on matching between this query and indices.
As another example, a complex data structure thesaurus can be used to identify data processing systems that use certain objects and/or identifiers. Such “where-used” checks can be used, e.g., for a corporate wide reporting of purchasing costs of a single product to identify if centralized “buying in bulk” can be used to lower the cost of that product.
As another example, a complex data structure thesaurus can be used in global searches and central searches with downstream identification translation. Such searches located objects by the attributes of a central object and then determine the identifier of the local representation.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. Accordingly, other implementations are within the scope of the following claims. | 4y
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BACKGROUND
[0001] The invention relates generally to the field of power supply and distribution, such as that to and with motor control centers. Specifically, the invention relates to techniques for connecting incoming power supply to certain types of electrical machinery.
[0002] Systems that distribute electrical power for residential, commercial, and industrial uses can be complex and widely divergent in design and operation. Electrical power generated at a power plant may be processed and distributed via substations, transformers, power lines, and so forth, prior to receipt by the end user. The user may receive the power over a wide range of voltages, depending on availability, intended use, and other factors. In large commercial and industrial operations, the power may be supplied as three phase AC power (e.g., 208 to 690 volt AC, and higher) from a main power line to a power management system. Power distribution and control equipment then conditions the power and applies it to loads, such as electric motors and other equipment. In one exemplary approach, collective assemblies of protective devices, control devices, switchgear, controllers, and so forth are located in enclosures, sometimes referred to as “motor control centers” or “MCCs”. Though the present technique is discussed in the context of MCCs, the technique may apply to power management systems in general, such as switchboards, switchgear, panelboards, pull boxes, junction boxes, cabinets, other electrical enclosures, and so forth.
[0003] The MCC may manage both application of electrical power, as well as data communication, to the loads, such loads typically including various machines, actuators and motors. Within the MCC may be disposed a variety of components or devices used in the operation and control of the loads. Exemplary devices contained within the MCC are motor starters, overload relays, circuit breakers, and solid-state motor control devices, such as variable frequency drives, programmable logic and automation controllers, and so forth. The MCC may also include relay panels, panel boards, feeder-tap elements, and the like. Some or all of the devices may be affixed within various “units” (or “buckets”) within the MCC. The MCC typically includes a steel enclosure built as a floor mounted assembly of one or more vertical sections containing the units or buckets. An MCC vertical section may stand alone as a complete MCC, or several vertical sections may be positioned and bused together. Exemplary vertical sections common in the art are 20 inches wide by 90 inches high.
[0004] The MCC normally interfaces with (and contains) power buses and wiring that supply power to the units and components, as sell as from the components to the loads. For example, the MCC may house a horizontal common power bus that branches to vertical power buses at each MCC vertical section. The vertical power buses then extend the common power supply to the individual units or buckets. To protect the power buses from physical damage, both the horizontal and vertical buses may be housed in enclosures, held in place by bus bracing or brackets, bolted to molded supports, encased in molded supports, and so forth. Other large power distribution equipment and enclosures typically follow a somewhat similar construction, with bus bars routing power to locations of equipment within the enclosures.
[0005] To electrically couple the MCC units or buckets to the vertical bus, and to simplify installation and removal, the units may be provided with self-aligning electrical connectors or metal “stabs” on the back of each unit. To make the power connections, the stabs, which may comprise spring-supported clamp devices, engage metal bus bars or conductive elements connected to the bus bars. For three phase power, three stabs per unit may accommodate three bus bars for the incoming power to provide power at the units. An optional ground or neutral bus may also be used. Within the unit, three stab wires or power lead wires may route power from the stabs to a disconnecting device or component, typically through protective devices such as fuses and circuit breakers. It should be noted that though three phase AC power is discussed, the MCCs may also manage single phase AC power, as well as DC power (e.g., 24 volt DC power for sensors, actuators, and data communication). Moreover, the individual units or buckets may connect directly to the horizontal common bus by suitable wiring and connections.
[0006] One continuing issue in such systems ensuring the quality of the electric connection made between the stab and the bus bars disposed on the vertical bus. The bus bars are traditionally made of copper or allow material to facilitate the flow of electricity. A separate spring or clamp is then generally used to hold the bus bars in intimate contact with the stab. However, this method can be costly and cumbersome, and may not offer optimal connectivity over time. In particular, the spring forces that serve to ensure good connections may not be consistent, consistently distributed, and may decay over time due to material creep, temperature variation, and so forth. Thus, there is a need for a more efficient and effective means of disposing a stab in intimate contact with a stab receptacle.
BRIEF DESCRIPTION
[0007] In an exemplary embodiment, an electric power stab system includes first and second conductors disposed in mutually facing relation, each conductor comprising a conductive layer on an inner side of the conductor and a spring biasing layer bonded on an outer side of the conductor, the conductive layer comprising a metal of substantially higher conductivity than the spring biasing layer, the spring biasing layers urging the conductive layers towards a mating stab element when inserted between the first and second conductors for carrying electrical current primarily through the conductive layer.
[0008] In another embodiment, a similar system includes a conductive material bonded to a material of high elastic modulus, wherein portions of the bonded material face each other, conductive sides being on the inside and the high elastic modulus material being on the outside so that the conductive material is urged towards a contact position by the high elastic modulus material.
[0009] In another embodiment, a method includes bonding a conductive material to a spring steel material to form an electrical stab contact, wherein the conductive material is at least as thick as the steel material.
DRAWINGS
[0010] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0011] FIG. 1 is a perspective view of one embodiment of a stab fork assembly, in accordance with the present disclosure;
[0012] FIG. 2 is a detailed view of a tip of the stab fork assembly of FIG. 1 ;
[0013] FIG. 3 is a perspective view of an embodiment of an alternative stab fork assembly;
[0014] FIG. 4 is a perspective view of an embodiment of a further stab fork assembly;
[0015] FIG. 5 is a perspective view of an embodiment of another alternative stab fork assembly;
[0016] FIG. 6 is a perspective view of a stab fork assembly receiving a stab, in accordance with the present disclosure;
[0017] FIG. 7 illustrates an embodiment of a stab fork assembly having a continuous base;
[0018] FIG. 8 illustrates an embodiment of a stab fork assembly having a continuous base and inwardly curving tips;
[0019] FIG. 9 is a perspective view of a power stab system in functional relation to a stab connector device, in accordance with the present disclosure; and
[0020] FIG. 10 is a diagrammatical view of a method for making a stab fork assembly, in accordance with the present disclosure.
DETAILED DESCRIPTION
[0021] Referring generally to FIG. 1 , one embodiment of a stab fork assembly 10 is illustrated. The embodied stab fork assembly 10 includes two stab forks 12 disposed in generally mutually facing relation. Each of the stab forks 12 further comprises a base 14 , a body 16 comprising a plurality of fingers 18 separated by a plurality of slits 20 , and outwardly bending tips 22 where the fingers 18 terminate. The body 16 is generally disposed at an angle in relation to the base 14 . Specifically, the body 16 is generally vertically oriented, while the base 14 is generally horizontally oriented, or vice versa, depending on the viewing angle, as illustrated in FIG. 1 . The two tips 22 generally bend outwardly toward opposing directions, forming a primary contact region 24 between the stab forks 12 at the point of inflection of the outwardly bending tips. The primary contact region 24 is generally where a stab would first make contact with the stab fork assembly 10 during making of the connection. The base 14 of the stab forks 12 may include apertures 26 , as shown in FIG. 1 , or other forms of attachment mechanisms for securing the stab fork assembly 10 to a bus bar or other structure.
[0022] Still referring to FIG. 1 , the stab forks 12 are generally composed of a spring steel layer 28 and a conductive layer 30 . The conductive layer 30 is disposed on the inner side of each stab fork 12 such that when two stab forks 12 are disposed in mutually facing fashion, the conductive layer 30 of one stab fork 12 is facing the conductive layer 30 of the other stab fork 12 . Accordingly, the steel layer 28 of each stab fork 12 face outward and away from the stab fork assembly 10 .
[0023] Referring now to FIG. 2 , a detailed view of the tip 22 , the steel layer 28 and the conductive layer 30 are bonded together at a bond seam 32 . It is important to note that the neither the steel layer 28 nor the conductive layer 30 should be considered a coating or plating layer as is commonly used in some industries and applications, with one material being much less massive and thick than the other. Rather, the steel layer 28 and the conductive layer 30 of a stab fork 12 may be of relatively comparable mass, in which the conductive material is at least as thick as the steel material. Many factors, including the steel thickness and its elastic properties, the conductive material thickness, finger width 38 , finger length 40 , the number of fingers, and the desired contact force affect the performance of a stab fork assembly 10 .
[0024] The illustrated embodiments generally comprise one steel layer bonded to one conductive layer in the manner discussed. However, some other embodiments may have multiple layers of either material, and formed in ways different than the present embodiments. Moreover, in some configurations one or more layers of other material may be disposed between the two layers.
[0025] FIG. 3 shows another embodiment of a stab fork assembly 10 . This embodiment includes a base 14 , a body 16 , and tips 22 , in similar fashion to the stab fork assembly 10 embodiment illustrated in FIG. 1 . Additionally, the body 16 of the stab fork assembly shown in the FIG. 3 features a concave middle region 44 . The concave middle region 44 comprises an outward bend and an inward bend of the fingers 18 at a relatively higher point along the fingers, as more clearly illustrated in FIG. 3 . These bends do not include the outward bend of the tips 22 , which generally occurs at a higher point. The concave region may be formed or configured in a number of ways, as deemed desirable for particular applications. In one or more embodiment, a stab fork assembly 10 may comprise one or more concave regions 44 , with bends that may or may not be defined at “concave”, or that may be more or less so.
[0026] The body 16 of the stab fork assembly 10 may take on many configurations, as is determined suitable for the stab to be received and the environment in which it is used. Two such embodiments of the body 16 of a stab fork assembly are illustrated in the present disclosure, one having a straight body and one having a body comprising a concave region 44 . Some other embodiments may have alternate configurations such as multiple concave regions 44 , support bars, and so forth.
[0027] The base 14 of the stab fork assembly 10 is illustrated in the present embodiments as bending outward and away from the stab fork assembly 10 , and having apertures 26 for securing the base 10 to a bus bar or other fixture. Some other embodiments may feature bases 10 bending inward, towards the middle of the stab fork assembly, or some alternate configuration. In some embodiments, the bases 10 may be coupled together or formed from one piece. Further, the attachment mechanism may be something other than apertures 26 , such as that being used with clamps, clips, ties, and so forth.
[0028] FIG. 4 shows another embodiment of a stab fork assembly 10 . This embodiment features a fastening region 46 and fasteners 48 . This embodiment also features a first forked end 50 and a second forked end 52 , such that each stab fork 12 has two bodies, each comprising a plurality of fingers 18 , slits 20 , tips 22 disposed in laterally opposing relation. The fastening region 46 of each stab fork 12 is disposed between the first forked end 50 and the second forked end 52 . The first forked end 50 , the fastening region 46 , and the second forked end 52 are generally formed from a continuous piece of material, but need not be. As further shown in FIG. 4 , the fastening regions 46 of two stab forks 12 are generally fastened together by fasteners 48 such that the stab forks 12 are disposed in mutually facing relation with the conductive layer 30 of one stab fork facing the conductive layer 30 of the joining stab fork, and such that the tips 22 of each stab fork 12 bend outward and away from the tips 22 of the joining stab fork. The fastening regions 46 of the two stab forks are generally intimately secured to each other such that the two stab forks 12 move as one body.
[0029] FIG. 4 illustrates an embodiment of the stab fork assembly 10 having a first forked end 50 and a second forked end 52 being laterally connected to each other by a fastening region, such that the first forked end and the second forked end are disposed generally along the same plane. Some embodiments of a stab fork assembly 10 may be configured to have a first forked end 50 that is disposed at an angle to a second forked end 52 , rather than being disposed in a straight line. In such configurations, the fastening region 46 may be where the angle originates. Further, these embodiments may include a means of disposing the stab fork assembly 10 onto another fixture. Additionally, the bodies of the first forked end 50 and second forked end 52 are subject to a variety of configurations, such as being straight rather than having a concave region.
[0030] FIG. 5 illustrates one embodiment of the stab fork assembly 10 . Each stab fork 12 of this embodiment includes a base 14 , a body 16 featuring a plurality of fingers 18 , slits 20 , tips 22 , and a concave middle region 44 , similar to that the embodiment of FIG. 3 . Additionally, the stab forks 12 of the embodiment of FIG. 5 feature a fastening region 46 disposed above and adjacent to the base 14 . The two stab forks 12 are joined together at the fastening region 46 with fasteners 48 such that the stab forks 12 are in mutually facing relation with both sets of tips 22 pointing outward and away from each other. The fastening regions 46 of the two stab forks 12 are generally intimately secured to each other such that the two stab forks move as one body.
[0031] FIG. 6 illustrates an embodiment of a stab assembly 10 having received a stab 54 . The stab 54 is generally inserted into the stab fork assembly from the top, and travels laterally down the body 16 toward the base 14 until it is fully disposed. As the stab 54 makes contact with and is disposed through the primary contact regions 24 , the stab 54 and the stab fork assembly 10 become electrically coupled.
[0032] In some embodiments, the stab width 56 may be larger than the first contact distance 42 when the stab fork assembly 10 is in a neutral position but generally not larger than the largest distance between the tips 22 , which generally occurs at the very end of the tips 22 , such that the naturally outwardly bending tips guide the stab into the first contact region 24 . When the stab 54 is disposed past the first contact region 24 , the stab forks 12 are generally outwardly separated by the incoming stab. Neutral position refers to the position of a stab fork assembly 12 when it is not interacting with a stab or being subject to external forces with the exception of forces related generally to the attachment of the base 14 to a fixture. Since the base 14 of the stab fork assembly 10 may generally be secured such it does not move or separate when a stab is inserted, the widening of the first contact distance 42 generally causes an outwardly bending deformation in the body 16 or between the body 16 and the base 14 in order to accommodate the stab 54 . When the stab 54 is fully disposed in the stab fork assembly 10 , the first contact distance is generally the same as the stab width 56 . As the stab forks 12 are elastically deformed to accommodate the increase in the first contact distance when a stab 54 is inserted, a restoring or contact force is generated, which keeps the fingers 18 urged into contact with the inserted stab 54 . This contact force is generally determined by several factors relating to the shape, material, geometric configuration, dimensions, thickness and so forth of the fingers, as well as the number of fingers (or more generally, the width of the structure).
[0033] The first contact distance 42 ( FIG. 1 ) of a stab fork assembly 10 in neutral position is generally related to such factors as the distance between the two bases 12 , the degree of curvature between the base 12 and the body 16 , the length of the body 40 , and the configuration of the body, such as being straight or having structural elements such as a concave region. Likewise, the contact force on the stab by the stab fork assembly 10 depends generally on such factors as, in additional to the above, the elastic modulus of the stab fork assembly material, the geometric configuration of the stab fork assembly 10 (e.g., length, width, thickness, shape), and amount of displacement or deformation of the stab fork assembly 10 . Thus, different configurations may be used for different applications and to obtain different desired specifications, such as contact force, size, and so forth, as will be exercised by one skilled in the art. Accordingly, there is a high degree of design flexibility associated with the present disclosure while staying within the creative principles and essence of the present disclosure.
[0034] FIG. 7 illustrates another embodiment of the stab fork assembly 10 . This embodiment includes a continuous base 60 , which is formed by bending a continuous piece of material at two corners 62 . This also provides two upright stab fork walls 64 approximately perpendicular to the continuous base 60 for receiving the stab 54 . Additionally, this embodiment is generally configured such that the steel layer 28 is on the outside of the stab fork assembly 10 and the conductive layer 30 is on the inside of the stab fork. The steel layer 28 provides mechanical support and the conductive layer 30 makes contact with the inserted stab 54 .
[0035] FIG. 8 illustrates yet another embodiment of the stab fork assembly 10 . This embodiment includes a continuous base 66 and two upright stab arms which terminate at respective inwardly curved tips 68 , as illustrated. This embodiment is configured such that the steel layer 30 is generally on the inside of the stab fork assembly 10 and the conductive layer 28 is generally on the outside of the stab fork assembly 10 , such that the conductive layers 28 of the inwardly curved tips 68 are configured to be mutually facing. Such an embodiment allows the stab 54 to be in contact with the conductive layer 28 of the stab fork assembly 10 as the stab 54 is inserted into the stab fork assembly 10 . However, because the conductive layer 28 is generally on the outside of the stab fork assembly 10 , such as at the continuous base 66 , the stab fork assembly 10 may conduct power from the stab 54 to the outside of the continuous base 66 . This configuration allows the stab fork assembly 10 to be mounted on a bus bar with the conductive layer 28 of the continuous base 66 conducting power from the stab 54 to the bus bar.
[0036] FIG. 9 illustrates an embodiment of the stab fork assembly 10 as it may be used as a part of a power stab assembly. The power stab system 58 of this embodiment features three stab fork assemblies 10 mounted onto bus bars 70 , which are mounted onto a support 72 , generally to receive three-phase power. The bases 14 of the three stab fork assemblies 10 embodied here are mounted onto the bus bars via apertures 26 . The embodied power stab system 58 is generally used with a stab connector device 74 coupled to three stabs 54 . The stab connector device 74 and stabs 54 are configured in general alignment with the power stab system 58 such that when engaged, each stab 54 is inserted into the respective stab fork 10 , establishing a conductive connection.
[0037] The embodiments of FIG. 1-9 illustrate the stab fork assembly 10 as being comprised of two stab forks 12 of generally identical configurations or a stab fork assembly with a continuous base as illustrated in FIGS. 7 and 8 . This may be advantageous in some applications. However, one or more embodiments may utilize two dissimilar stab forks 12 to compose a stab fork assembly 10 . One such embodiment might mix one of the stab forks 12 embodied in FIG. 1 with one of the stab forks 12 embodied in FIG. 3 , such that the composed stab fork assembly comprises one stab fork 12 without a concave region 44 and one stab fork 12 with a concave region 44 . This as well as some other stab fork assembly configuration comprising two generally non-identical stab forks may be advantageous in the case that the stab to be received by the stab fork assembly 10 is configured differently on its two sides. Having a stab fork assembly 10 configured with 2 different stab forks, each configured in accordance with the respective side of the stab, would possibly provide a more robust connection.
[0038] Another embodiment of the stab fork assembly 10 may comprise only one stab fork 12 disposed in mutually facing relation with a non-forked support (not illustrated). Unlike the two stab forks illustrated in the figures, one stab fork may be replaced by a non-forked support, such that when the stab and stab fork assembly 10 are fully disposed, one side of the stab is in contact with the stab fork 12 , and the other side of the stab is in contact with a non-forked support.
[0039] FIG. 10 illustrates via a flowchart an embodiment of a method for making a stab fork assembly. The process begins with raw materials of steel 76 , such as spring steel, and a highly conductive material 78 , such as copper. In the present embodiment, the two materials are first bonded to each other, as indicated by reference numeral 80 . This may generally be done through explosive bonding or some other techniques of intimately bonding two materials. The next step in this embodiment is to flatten the bonded material, as indicated at step 82 . The materials may be bonded in a generally flattened state, and the bonded combination may then be processed (e.g., rolled or otherwise flattened or worked) to the desired thickness of the stab fork 12 . In the present embodiment, the general shape of the stab forks is cut, as indicated by reference numeral 84 , and then the details of the stab fork are formed (e.g., cut), as indicated by reference numeral 86 . For example, the general shape of a stab form refers to the main outline of the stab 12 , excluding the individual slits 20 and the apertures 26 . This division of steps may be advantageous since many embodiments of the stab fork assembly 10 may include stab forks 12 of identical general shape, but differing details such as number of forks 18 and apertures 26 . This way, several embodiments may be mass manufactured together until the steps relating to cutting or forming the detailed features, saving time and resources. In the present embodiment, the cut out shapes are then bent at step 88 into desired stab fork shapes, generally involving outwardly bending tips, loosely perpendicularly bent bases, concave regions in some embodiments, and other configurations more illustrated in the present disclosure. In one presently contemplated embodiment, the entire surface of the stab fork may be plated, such as with silver or some other material to lower contact resistance, avoid fretting, and prevent oxidation as indicated at step 90 . The finished structure may then be lubricated to guard against possible corrosive environments and reduce friction, as indicated at step 92 . The above embodiment of a method for making a stab fork assembly illustrates one possible configuration of steps. Other possible embodiments may combine steps, further separate steps, switch the order of some steps, and add or remove steps while maintaining the essence of the present disclosure.
[0040] As mentioned above, the bonding of the copper and steel materials, as indicated by reference numeral 80 , may be accomplished through explosive bonding. In the explosive bonding process, a first material is placed on top of a second material, leaving a small distance in between to allow for acceleration. Explosive material is typically placed on top of the first material such that when ignited, the explosive force causes the first material to be accelerated towards the bottom material, obtaining a very high impact velocity when it collides with the second material. The impact results in high localized pressure of the first material onto the second material, bonding the two materials. Explosive bonding generally produces a robust bond while maintaining the characteristics of each bonded material. This may be advantageous as the present invention benefits from the elastic and strength characteristics of the steel material as well as the conductive characteristics of the copper material. Explosive bonding may also aid in maintaining a solid bond between the dissimilar materials, and reduce the risk of separation or delamination during later working and use.
[0041] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. provisional application having Ser. No. 61/798,551, filed on Mar. 15, 2013, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This disclosure relates generally to electrical circuits, and more particularly to a radio frequency (RF) transmission apparatus with reduced power consumption.
2. Description of Related Prior Art
FIG. 1 , panel A, depicts a top view of a conventional wireless communication device 100 . Common wireless communication devices include cellular phones, wireless networking devices, wireless handsets, personal digital assistants (PDAs), laptop and desktop computers, routers, and key fobs. As shown, the wireless communication device 100 includes a battery 102 , a digital signal processor (DSP) 104 , a transceiver 106 , a power amplifier 108 , an antenna 110 , and other electronic circuitry 112 . The battery 102 provides direct current (DC) power to other device components. The digital signal processor (DSP) 104 manipulates communication signals between analog and digital signal processing domains, while the transceiver 106 up and down converts the communication signals between low frequencies and RF frequencies. The power amplifier 112 amplifies a power of the signal output from the transceiver to drive a transmission signal into the antenna 110 . In turn, the antenna 110 transmits the transmission signal into free space. A receiver of another wireless communication device (not shown) may receive the radiated signal through a receiver antenna and process the received signal, thus allowing wireless communication of information between the wireless communication device 100 and the other wireless communication device.
Panel B depicts a side view of the conventional wireless communication device 100 . As shown, the antenna 110 and electronic circuitry components 140 (e.g., the DSP 104 , the transceiver 106 , etc.) are mounted on a substrate 130 such as a printed circuit board (PCB). In addition, the wireless communication device 100 includes an electrical shield 150 which can serve two purposes: (1) preventing internally generated electrical signals from radiating out to affect the function of other components; and (2) preventing externally generated electrical signals from radiating in to affect the function of the components 140 .
FIG. 2 depicts an enclosure of a convention wireless communication device. Panel A shows a wireless phone device 200 and panel B shows a wireless tablet device 250 . As illustrated in panel A, the wireless phone device 200 includes antenna(s) 210 for transmitting and/or receiving radio frequency signals. The wireless phone device 200 further includes a key pad 220 for tactile input and a display screen 230 for display and/or tactile input. Although a physical key pad 220 is shown, the wireless phone device 200 may alternatively include a virtual key pad (not shown), which is a software component that permits key stokes to be made via, e.g., a touch screen. In addition, the wireless phone device 200 includes casing which holds all the electronic components and component mounting substrates of the wireless phone device 200 . The casing may also electrically isolate the internal components of the wireless phone device 200 from the exterior. A back cover (not shown) of the wireless phone device 200 may also include casing made from various materials. Similarly, the wireless tablet device 250 includes antenna(s) 260 , a key pad 270 (or a virtual keypad), and a display screen 280 which may generally perform the same functions as the antenna(s) 210 , the key pad 220 , and the display screen 230 of the wireless phone device 200 . In addition, the wireless tablet device 250 may also include a casing that encloses electronic components and component mounting substrates and electrically insulates these components, as well as a back cover.
SUMMARY OF INVENTION
Embodiments of the invention described herein enable radio frequency (RF) transmission devices to receive transmission power that is radiated onto the surfaces of the devices. In one embodiment, a wireless device is provided. The wireless device includes a transmitter having a transmitter antenna and configured to transmit a signal. The wireless device also includes an energy receiver having a plurality of energy receiver antenna elements positioned across one or more surfaces of the wireless device. The energy receiver antenna elements are each configured to receive a portion of the signal, convert the portion of the signal into (DC) power, and provide the (DC) power to one or more components of the wireless device.
In another embodiment, a wireless device is provided that includes a transmitter having a transmitter antenna and an energy receiver antenna. The transmitter antenna is configured to transmit a signal. The wireless device also includes an energy receiver having a receiver antenna and configured to receive a portion of the signal, convert the portion of the signal into power, and provide the power to one or more components of the wireless device. The receiver antenna is configured as a weakened antenna which does not efficiently receive the portion of the signal.
In yet another embodiment, a wireless device is provided that includes a transmitter having a transmitter antenna and an energy receiver having first and second receiver antennas. The transmitter antenna is configured to transmit a signal. The first and second receiver antennas are configured to receive a portion of the signal, convert the portion of the signal into power, and provide the power to one or more components of the wireless device. Frequency centers of the transmitter antenna and the first receiver antenna are matched, while frequency centers of the transmitter antenna and the second receiver antenna are not matched.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 illustrates top and side views of a conventional wireless device.
FIG. 2 depicts an enclosure of a convention wireless communication device.
FIG. 3 is a block diagram of a wireless communication device configured to receive power from its own transmissions, according to an embodiment.
FIG. 4 illustrates matched energy receiver antennas substantially covering the surface of a wireless communication device, according to an embodiment.
FIG. 5 illustrates mismatched energy receiver antennas substantially covering the surface of a wireless communication device, according to an embodiment.
FIG. 6 illustrates combining matched and mismatched energy receiver antennas to substantially cover the surface of a wireless communication device, according to an embodiment.
FIG. 7 illustrates use of energy receiver antennas as electrical shields in a wireless communication device, according to an embodiment.
For clarity, identical reference numbers have been used, where applicable, to designate identical elements that are common between figures. It is contemplated that features of one embodiment may be incorporated in other embodiments without further recitation.
DETAILED DESCRIPTION
FIG. 3 depicts a wireless communication device 302 configured to receive power from its own transmissions, according to an embodiment. As shown, the wireless communication device 302 includes direct current (DC) power source(s) 306 that provide power to a modulator 310 , power amplifier(s) 312 , and components performing other functions of the wireless communication device transmitter (TX) 308 which may include a transmit processor having a time variant transmit carrier frequency or frequencies (Fc or Fc(s)). The wireless communication device 302 further includes (optional) regulators 314 , 316 , 318 that respectively provide correct voltage and/or current regulation to the components 308 , the modulator 310 , and the power amplifier(s) 312 . The modulator 310 may include a voltage controlled oscillator and phase lock loop to select a given transmit frequency from a range of possible transmit frequencies. The power amplifier 312 amplifies a power of a modulated signal output from the modulator 310 . The output of the power amplifier 312 (also referred to herein as “TX signal power”) is transmitted through a transmit antenna 328 into free space. Remote receiver antenna(s) 332 may then receive the radiated signal and process the received signal, thus allowing wireless communication of information between the wireless device 302 and the remote wireless device 340 .
RF transmit (TX) signal power radiated by transmit antenna(s) 328 may be high in order to compensate for the distance from remote receiver antenna(s) 332 and to compensate for any signal power lost due to DC power signal(s) circuitry objects blocking the signal path. As is well known, RF signal power degrades by distance squared. For example, if transmit antenna(s) 328 transmit 1-2 Watts of RF signal power, the remote receiver antenna(s) 332 might only receive a few uW of RF signal power. This low level of RF signal power is typically enough for functional wireless communication.
As shown, the wireless communication device 302 includes an energy receiver 320 that includes an energy receiver (ERX) antenna 330 and energy receiver circuitry element(s) 322 configured to receive a time variant communication signal and alternating current (AC) to DC converter(s) 324 configured to convert the received communication signal into DC power. That is, RF transmission signal power generated by the transmit antenna(s) 328 is received and converted into DC power which can provide electrical power to the wireless device 302 for operation and/or battery charging. The energy receiver 320 further includes a DC power management circuit 326 that can provide proper voltage levels of DC power to circuits (or components) within the wireless communication device 302 .
As shown, the energy receiver antenna(s) 330 are placed within a short, fixed distance D short (s) from transmit antenna(s) 328 . Because the distance between the transmit antenna(s) 328 and the energy receiver antenna(s) 330 is short, a substantial amount of transmission signal power can be received at the energy receiver antenna(s) 330 and converted for DC power use. One approach for receiving and converting such transmission signal power is described in U.S. Pat. No. 8,416,721, which is hereby incorporated by reference in its entirety.
FIG. 4 illustrates matched energy receiver antennas substantially covering the surface of a wireless communication device 400 , according to an embodiment. As shown in panel A, the wireless communication device 400 includes transmit antenna(s) 402 and one or more matched energy receiver antenna(s) 404 covering a surface of the wireless phone device 400 . Illustratively, the frequency of the energy receiver antenna(s) 404 are deliberately matched to the transmission frequency of the wireless device's 400 own transmit antenna(s) 402 . Panel B illustrates a graph of the transmission signal power spectral envelope density versus frequency in the wireless communication device 400 having energy receiver antenna(s) 404 matching the frequency of transmit antenna(s) 402 . As shown, the frequency 401 of the energy receiver antenna is matched to the frequency center of the transmit antenna. The matching of the frequency of the energy receiver antenna(s) 404 to the transmission frequency of the transmit antenna(s) 402 permits the energy receiver antenna(s) 404 to most efficiently receive the transmission power radiated onto the surface of the wireless phone device 400 .
In one embodiment, the surface of the wireless device 400 may be maximally covered by energy receiver antenna(s) 404 , except for areas needed for other critical functions, such as the screen, key pad, and transmit/receiver antennas. In another embodiment, energy receiver antenna(s) 404 may also be placed under the key pad, screen, etc. Trial and error and/or antenna software simulation may be used to determine the spacing needed between energy receiver antenna(s) 404 and transmit antenna(s) 402 to prevent interference to the transmission and receiving functions required by the wireless device 400 . More specifically, an effective distance between the energy receiver antenna(s) 404 and the transmit/receiver antenna(s) may be determined based on various optimization factors, such as maximizing the energy received, with the least amount of interference to the transmission, and placing the energy receiver antenna(s) at an effective distance to the transmit antenna(s) 404 .
Experience has shown that, in a particular embodiment, a 34% power consumption reduction was achieved when the surface of a typical wireless device was covered with matched antenna(s), with the entire back surface and the left, right, and bottom sides covered with matched antenna(s) and only the keypad, screen and half an inch within the transmit/receiver antenna being left un-covered. Further, no significant transmission/reception signal impairment was measured.
FIG. 5 illustrates mismatched energy receiver antennas substantially covering the surface of a wireless communication device 500 , according to an embodiment. As shown, the wireless communication device 500 includes antenna(s) for transmission of signals as well as energy receiver antenna(s) 504 configured to receive transmission power from the transmit antenna(s) 502 so that the transmission power can be converted to energy for use by the wireless communication device 500 .
The energy receiver antenna(s) 504 are deliberately weakened so as to not efficiently receive the transmission power radiated by the transmit antenna 502 (s). A number of organic and non-organic materials such as human tissue, printed circuit boards, wireless device casing, are capable of absorbing radiated RF transmission power to varying degrees. For example, human tissue acts as an inefficient antenna which does not match a transmit antenna frequency center. In one embodiment, the energy receiver antenna(s) 504 may be constructed from such materials.
In another embodiment, energy receiver antenna(s) 504 may be deliberately weakened by shifting the frequency center of the energy receiver antenna(s) 504 away from the frequency center of the transmit antenna(s) 502 by, e.g., calibrating the energy receiver antenna(s) 504 to be mismatched with the transmit antenna(s) 502 . Panel B illustrates a graph of the transmission signal power spectral envelope density versus frequency in the wireless communication device 500 having mismatched energy receiver antenna(s) 504 . This mismatching makes the energy receiver antenna(s) 504 less efficient at receiving the transmission power radiated onto the surface of the wireless device 500 . As a result, one or more mismatched energy receiver antenna(s) 504 may be placed next to the transmit/receiver antenna 502 , at a closer distance than matched energy receiver antennas could be placed, without affecting normal RF functions. Because transmission RF power degrades by distance squared, less efficient energy receiver antennas placed closer to the transmit antenna(s) 502 may actually be equal to or more efficient than matched energy receiver antennas placed further away from the transmit antenna(s) 502 .
Illustratively, the wireless device 500 is maximally covered by the mismatched energy receiver antenna(s) 504 , except for regions needed for other critical functions, such as a key pad, display screen, and transmit/receiver antenna(s). In another embodiment, energy receiver antenna(s) may also be placed underneath the key pad and/or the display screen. If necessary to prevent interference to transmission/reception functions, the spacing between the energy receiver antenna(s) 504 and transmit/receiver antennas may be obtained by trial and error and/or antenna software simulation.
Experience has shown that in a particular embodiment, in which a wireless devices with non-matching transmit antennas having different communication standards/frequencies than energy receiver antennas were placed in close proximity to the energy receiver antennas, the energy receiver antennas still received non-matching transmission power which could be converted to DC power. In addition, no substantial transmission/reception signal power degradation was measured.
FIG. 6 illustrates combining matched and mismatched energy receiver antennas to substantially cover the surface of a wireless communication device 600 , according to an embodiment. As shown in panel A, the wireless communication device 600 includes two rows of mismatched, and deliberately less efficient, antenna(s) 604 placed close to the wireless device's 600 transmit antenna(s) 602 . As discussed, the deliberately less efficient antenna(s) 604 may be, e.g., made of materials capable of absorbing radiated RF transmission power but not interfering with transmission or reception of RF signals. The less efficient antenna(s) 604 may also have frequency center(s) that are mismatched with frequency center(s) of the transmit antenna(s) 602 . The wireless device 600 also includes rows of matched antennas 606 placed further away from the wireless device's 600 transmit antenna(s) 602 than the mismatched antenna(s) 604 are placed. As discussed, the matched antenna(s) 606 can receive radiated transmission power more efficiently than the mismatched antennas 604 . Panel B illustrates a graph of the transmission signal power spectral envelope density versus frequency in the wireless communication device 600 having both matched energy receiver antenna(s) 606 and mismatched energy receiver antenna(s) 604 . Once again, to prevent interference to the transmission/reception functions of the wireless device 600 , the spacing needed between energy receiver antenna(s) 604 , 606 and transmit/receiver antenna(s) may be obtained by trial and error and/or antenna software simulation. By using both mismatched antennas 604 and matched antennas 606 , it is possible to maximize the space on the surface of the wireless device 600 on which energy receiver antennas are placed.
FIG. 7 depicts use of energy receiver antennas as electrical shields in a wireless communication device 700 , according to an embodiment. As shown, the wireless communication device 700 includes a transmit antenna 710 and electronic circuitry components 740 mounted on a substrate 730 . The transmit antenna 710 , electronic circuitry components 740 , and substrate 730 may be similar to the transmit antenna 110 , electronic circuitry components 140 , and substrate 130 of the wireless communication device 100 , discussed above. Rather than the electrical signal shields 150 of the wireless communication device 100 , however, the wireless communication device 700 includes energy receiver antennas 750 . The energy receiver antenna(s) 750 may have any feasible shape, including the same shape as the electrical signal shields 150 . In addition to receiving radiated transmission power, the energy receiver antenna(s) 750 may also perform the same function as the electrical signal shields 150 , namely preventing internally generated electrical signals from radiating out and affecting the function of other devices and preventing externally generated electrical signals from radiating in to affect the function of the electronic circuitry components 740 . As a result, energy receiver antennas 750 may replace electrical signal shields which are grounded. Replacing such electrical signal shields with energy receiver antennas 750 permits maximal use of available space for energy receiver antennas.
Advantageously, wireless devices disclosed herein include energy receiver antennas that receive the wireless devices' own transmission signals that are radiated onto the surfaces of the wireless devices. The received transmission signals are then converted to DC power that can be provided to various components of the wireless devices. Doing so reduces power consumption by the wireless devices and extends battery life.
While the forgoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. | 4y
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FIELD OF THE INVENTION
The present invention relates to a method for controlling an injection system of an internal combustion engine having at least one injector and to a corresponding control unit.
BACKGROUND INFORMATION
In fuel injection systems, of self-igniting engines in particular, the fuel quantities injected by injectors into the combustion chambers are divided into a plurality of partial injections. The partial injections usually follow one another in a rapid succession and may include one or more pilot injection(s) applied before a main injection. The time interval between two partial injections is implemented by the pause time between two electric trigger pulses of the injectors. The partial injections make improved mixture preparation and thus lower exhaust gas emissions of the engine, lower noise development during combustion, and higher mechanical power output of the engine possible.
In the case of the above-mentioned partial injections, the accuracy of the injected quantities is of great importance. However, each injection causes a brief drop in the fuel pressure in a fuel line connecting a high-pressure accumulator, known as a rail, to the corresponding injector. Such a pressure drop results in a fuel pressure wave between the rail and the injector after the end of the injector triggering; the effect of this wave on the injected quantity of the subsequent partial injections diminishes with an increasing time interval between the particular successive injections. This pressure wave effect intensifies with increasing lift frequency of the nozzle needle of the injector, so that taking it into account, also in future injector systems in particular, in which high-speed piezoelectric actuators are used as injection actuators for nozzle needle control in the particular injector, becomes increasingly important.
Since the above-described pressure wave phenomenon is of a highly systematic nature, and although it essentially depends on the time interval between the corresponding injection(s), the injected fuel quantity, the hydraulic fuel pressure, and the fuel temperature in the rail, compensation via an appropriate control function in the engine control unit may be implemented. In a method described in German Patent Application No. DE 101 23 035 for minimizing the pressure wave effect, the effect on the injected quantity of the particular injector is measured and the results of this measurement are taken into account in presetting the control data of the injector, specifically based on a previously empirically, i.e., experimentally, determined fuel quantity wave as a function of the time interval between the partial injections involved. The measured effect of the quantity on a subsequent injection is stored in characteristic maps, and the effect of the quantity is then compensated during the operation of the engine by appropriately modifying the duration of the energized state of the actuator which effects the subsequent injection.
The characteristic map is filled with data experimentally by measurements on a hydraulic test bench. The quantities influenced are ascertained in the form of “quantity waves” as a function of the interval between the corresponding injections and used for filling the characteristic map with the aid of a special algorithm. The excess or reduced quantities thus ascertained are stored in the above-mentioned characteristic maps and compensated during the operation of a control program of the engine by making the appropriate deductions in a quantity path of the engine control.
In the above-mentioned pressure wave correction, in principle a number of input and output quantities must be taken into account, the exact relationship between these quantities being extremely complex, since there are mutual dependencies such as interactions between the input quantities in particular. For this reason, considerable simplifications are necessary in the pressure wave correction to map the pressure wave phenomenon using the fewest possible characteristics maps; therefore, when mapping the pressure wave system, a considerable portion of the correction accuracy that would be possible in principle is lost.
It is therefore desirable to improve a method of the type mentioned above in such a way that a more accurate pressure wave correction than in the related art is made possible, which takes into account the largest possible number of input and/or output quantities in the pressure wave correction, omitting the fewest possible factors considered negligible, while using the least possible technical complexity at the same time.
SUMMARY OF THE INVENTION
The present invention is based on the idea of performing the pressure wave correction on the basis of a model which takes into account the empirically found fact that it is possible to represent the quantity waves as a continuously oscillating system. The basic idea of the present invention is that the quantity wave is modeled as a sum of a plurality of periodic functions. A great advantage of the method according to the present invention for controlling an injection system of an internal combustion engine is its simple and easily reproducible pressure wave correction structure, which makes it possible to considerably improve the correction accuracy compared to the methods known from the related art. In principle, the pressure waves may be modeled using the most diverse periodic functions.
In an advantageous embodiment of the present invention, the periodic functions are sine functions.
The periodic functions are preferably decaying periodic functions, i.e., sine functions that decay over time, for example. The parameters of the sine function, in particular its frequency, amplitude, damping, zero point displacement, and the like are advantageously determined as a function of the pressure and/or the quantity of the first partial injection and/or the quantity of the at least second partial injection, these functions being determined by adaptation to tests or simulations. The sine function parameters are advantageously stored in a memory of a control unit, which ensures that they are promptly accessible during the operation of the engine.
The quantity of a partial injection following a preceding partial injection which triggers a pressure wave is corrected. This makes a direct pressure wave correction possible.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows a common rail injection system which is known from the related art and is suitable for use in the present invention.
FIG. 2 schematically shows a longitudinal partial section through a fuel injector of an injection system depicted in FIG. 1 .
FIG. 3 shows an injection sequence, known per se, having a main injection and a pilot injection using appropriate triggering signals of an injection actuator, in particular for illustrating the pressure wave effect.
FIG. 4 schematically shows the quantity wave plotted against time and a function of the quantity wave, adapted using the method of the present invention, plotted against time.
DETAILED DESCRIPTION
FIG. 1 shows the components of a high-pressure based fuel injection system necessary for understanding the present invention using the example of a common rail (CR) injection system. A fuel reservoir is labeled with the numeral 1 . Fuel reservoir 1 is connected to a second filter 15 for pumping fuel via a first filter 5 and a presupply pump 10 . From second filter 15 the fuel is pumped to a high-pressure pump 25 via a line. The connecting line between second filter 15 and high-pressure pump 25 is also connected to the reservoir 1 via a connecting line having a low-pressure limiting valve 45 . High-pressure pump 25 is connected to a rail 30 . Rail 30 is also known as a (high-pressure) accumulator and is in turn connected in a pressure-conducting manner to different injectors 31 via fuel lines. Rail 30 is connectable to fuel reservoir 1 via a pressure release valve 35 . Pressure release valve 35 is controllable by a coil 36 .
The lines between the discharge of high-pressure pump 25 and the inlet of pressure release valve 35 are referred to as a “high-pressure area.” The fuel is under high pressure in this area. The pressure in the high-pressure area is detected with the aid of a sensor 40 . In contrast, the lines between fuel reservoir 1 and high-pressure pump 25 are referred to as a “low-pressure area.” A controller 60 sends trigger signal AP to high-pressure pump 25 , trigger signals A to each injector 31 , and/or a trigger signal AV to pressure release valve 35 . Controller 60 processes different signals of various sensors 65 , which characterize the operating state of the engine and/or of the motor vehicle propelled by this engine. Such an operating state is, for example, speed N of the engine.
The injection system depicted in FIG. 1 operates as follows. The fuel stored in fuel reservoir 1 is pumped by presupply pump 10 through first filter 5 and second filter 15 . If the pressure in the above-mentioned low-pressure area increases to inadmissibly high levels, low-pressure limiting valve 45 opens and clears the connection between the discharge of presupply pump 10 and reservoir 1 . High-pressure pump 25 pumps fuel quantity QI from the low-pressure area into the high-pressure area. In doing so, high pressure pump 25 builds up a very high pressure in rail 30 . Normally, maximum pressure values of approximately 30 bar to 100 bar are achieved for injection systems of externally ignited engines and 1000 bar to 2000 bar for self-igniting engines. The fuel may thus be metered to the individual combustion chambers (cylinders) of the engine under high pressure using injectors 31 . Pressure P rail in the rail, i.e., in the entire high-pressure area, is detected by sensor 40 . The pressure in the high-pressure area is regulated using controllable high-pressure pump 25 and/or pressure release valve 35 . Electric fuel pumps are normally used as presupply pump 10 . For pumping higher quantities, which are required for utility vehicles in particular, a plurality of presupply pumps connected in parallel may also be used.
FIG. 2 shows a piezoelectrically driven injector 101 described in German Patent No. DE 100 02 270 in partial section. Injector 101 has a piezoelectric unit 104 for operating a valve element 103 axially movable in a bore 113 of a valve body 107 . Injector 101 also has an adjusting piston 109 next to piezoelectric unit 104 and an operating piston 114 next to a valve closing element 115 . A hydraulic chamber 116 operating as a hydraulic transmission is situated between pistons 109 , 114 . Valve closing element 115 cooperates with at least one valve seat 118 , 119 and separates a low-pressure area 120 from a high-pressure area 121 . An electric control unit 112 , shown only schematically, delivers the trigger voltage for piezoelectric unit 104 as a function of the prevailing pressure level in high-pressure area 121 . An outflow throttle 130 and an inflow throttle 131 are additionally situated in high-pressure area 121 of injector 101 . The outflow/inflow adjustment ratio of these two throttles 130 , 131 is set with the aid of a control valve 132 .
FIG. 3 shows typical trigger signal curves for an injector shown in FIGS. 1 and 2 in the case of a main injection 200 and a preceding pilot injection 205 . The five signal curves shown represent different triggering states over time, in which the time interval (electrical pause time) between the two trigger signals 200 , 205 , viewed from above downward, is reduced stepwise to a minimum value delta_t_min. Let us now assume that the time interval resulting from the calibration, delta_t_start, is selected in such a way that a pressure wave in the rail caused by pilot injection 205 has decayed again by the time main injection 200 is triggered. Such values are known beforehand in the form of empirical values. Let us furthermore assume that time difference delta_t_min between the injections represented by the lowermost curve corresponds to a minimum time interval in which the pressure wave caused by pilot injection 205 already results in a measurable change in a performance quantity, preferably in a change in the torque of the engine.
Of course, the two injections depicted in FIG. 3 are only for illustration purposes, and therefore the method according to the present invention is also applicable to the calibration of a plurality of injections over time; even individual successive pilot injections may be influenced as described here because of the pressure waves.
The above-mentioned pressure wave effect may be explained with reference to FIG. 3 as follows. If pilot injection ‘VE’ 205 is separated from main injection ‘HE’ 200 by a sufficiently long time interval, i.e., in this case by the interval delta_t_start, the pressure wave triggered by it has already decayed by the time of main injection 200 and therefore no longer has any effect on the fuel quantity injected during the main injection. Because of the wave velocity, which is, as is known, pressure-dependent, this time interval is essentially a function of the instantaneous pressure in the rail, among other things. An empirically ascertained suitable starting value for delta_t_start is >2 ms. If the above-mentioned time interval is now varied by keeping the start of the main injection triggering constant but moving the time of the pilot injection closer to the main injection, the main injection quantity will be influenced starting at a certain time interval since, because of the pressure wave, the pressure, in particular in the area of the injector nozzle needle shown in FIG. 2 at the time of and during opening of the nozzle needle, is either increased due to a wave crest or reduced due to a wave valley. This results in a quantity effect or torque effect, which may be sensed via a speed signal of the engine, for example. Alternatively, the quantity effect may also be sensed, as is known, via a lambda sensor or its controller.
The pressure wave correction according to the present invention is performed by the following steps:
a. In a system simulation, the quantity waves are determined for a certain number of combinations of pilot injections, main injections, and rail pressures; b. the quantity waves are adjusted by a sum of two sine functions (see FIG. 4 , where the quantity wave in the 800 bar rail pressure and a function thus adjusted plotted against time are depicted); c. the parameters of the sine function, i.e., for example, the frequency, amplitude, damping, and zero point displacement, for example, may be almost fully represented as a function of the pressure and/or of the pilot injection quantity and/or the main injection quantity, for example; these functions are also adjusted; d. the functions ascertained in points b. and c., and possibly other non-correlatable quantities, are stored in the memory of control unit 60 ; e. the quantity is then corrected in the control unit as follows: The requested main injection quantity, pilot injection quantity, time difference, and rail pressure are used to determine the actual quantity. The quantity request is corrected accordingly. To achieve higher accuracy, this procedure may be iteratively repeated. | 4y
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FIELD OF THE INVENTION
The present invention concerns a soundproofed gear box, in particular a transmission gear box.
BACKGROUND OF THE INVENTION
The acoustic energy generated by rotating moving mechanical parts together with their bearings is transmitted in the form of airborne and structure-borne noise by the housing in which these mechanical elements are accommodated. In this process, some of this acoustic energy is directly transmitted as airborne acoustic energy, whereas the remainder, which is usually the greater part, is transmitted through the structure to the foundation supports of the mechanical assembly concerned. This structure-borne acoustic energy generates airborne acoustic energy in turn, as it is transmitted from the floor into the room.
The application of continuously more severe regulations aimed at restricting noise levels have obliged machinery designers to adopt designs characterized by especially efficient soundproofing.
The following methods of soundproofing are known to practitioners of the state of the art:
Friction soundproofing at the interfaces or mating faces of the various components, resulting in an increase of the transitional resistance;
Supplementary soundproofing of moving mechanical parts as well as of the walls of housings by the application of one or several coatings of soundproofing material, such as sound deadening or sandwich materials, by lining particular recesses and hollow spaces with soundproofing material as well as by the use of special vibration absorbers;
Internal or frictional soundproofing of the materials themselves, which is not applicable to metal components.
Ways are known of enhancing the dynamic rigidity of components by adopting thick-wall designs, thus providing a dimensionally and vibrationally stable structure whose energy flow paths are as short as possible.
The purpose of the present invention is to provide a simple way of effectively improving soundproofing.
SUMMARY OF THE INVENTION
The advantage of the present invention lies in that it provides an extremely long structure-borne acoustic path from the point of sound generation to the point of transit into the foundation, such that the amplitude of the acoustic energy generated will be substantially reduced along this long path as a result of the internal friction of the soundproofing material.
In a further embodiment of the present invention, the bearing carrier assembly may be connected only to the upper part of the housing in a unit in which the housing consists of a lower part with mounting feet together with an upper part.
The bearing carrier may be formed of two longitudinal members arranged at a distance from one another and divided in parts arranged above one another, each of the lower parts being connected to one another by means of cross members.
It is also possible for the bearing carrier to comprise two parts arranged at a distance from one another, each of these two parts being individually attached only to the upper part of the housing.
The bearing carrier assembly and/or the bearing carrier parts may in this case be fastened to the upper part of the housing by means of screws.
The upper part of the housing is preferably provided with recesses open towards the outside in which the screws are accommodated so as to be easily accessible from the outside.
In a further embodiment of the present invention, both the lower and upper parts of the housing may be provided with pairs of double walls and the internal cavities between them are filled with soundproofing material.
In yet a further embodiment of the present invention, lock bolts may be fitted in the lower part of the housing provided with double walls, whereby the lock bolts engage in bores in the bearing carrier assembly so as to be easily seen for inspection purposes, without the need to readjust new parts each time.
The present invention will now be elucidated with the heIp of embodiments and examples illustrated in the attached drawings, where:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a top view of a spur gear set according to the cross section I--I in FIG. 2;
FIG. 2 shows a view of the gear set along a line II--II in FIG. 1;
FIG. 3 shows a view of the gear set along a line III--III in FIG. 2;
FIG. 4 shows a longitudinal cross section of a planetary gear set; and
FIG. 5 shows a view of the gear box along a line V--V in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The spur gear set shown in FIGS. 1-3 consists essentially of a pair of rotating gear wheels 1 and 2 which are supported in plain bearings 3 and 4. These plain bearings are supported in longitudinal bearing carriers which are arranged parallel and at a distance from one another. All of these mechanical components are accommodated in a housing assembly 7 consisting of a lower and of an upper part 8 and 9 respectively. The bearing carrier parts 5 and 6 and/or 5' and 6' are fastened to one another by means of screws. This arrangement provides a bearing carrier assembly 11 which is fastened to the upper housing part 9 only by means of the screws 12. The housing 7 is provided with double walls 12 and 13 and/or 15 and 16 which are arranged roughly parallel to the corresponding longitudinal and transverse walls of the housing 7, as can be seen from FIGS. 2 and 3. The double walls 13, 14 and 15, 16 form internal cavities in the upper and lower parts of the housing (9, 8) which are in turn filled with highly efficient soundproofing material (17).
The housing 7 is provided with covers 18, 19 as shown in FIGS. 1 and 3. These covers serve to prevent the lubricating oil from escaping from the inside of the housing. The lower part of the housing 8 is provided with feet 20 which are attached to the bottom of the housing. As can be seen in FIG. 3, the upper part of the housing 9 is provided with recesses open towards the outside which insure easy access to the screws 12.
The lower bearing carriers 5, 5' of each of the bearing carrier assemblies 11 shown in FIG. 1 and 2 can be permanently attached to one another by means of the connecting walls 22, according to FIG. 2.
To allow the transmission to be inspected, stop screws 23 are provided in the lower part of the housing 8, as shown in FIG. 2, which are inserted in the threaded bores 24 in the bearing carrier parts 5, 5', for example, and serve to secure the bearing carrier assembly 11 in the housing 7 in all directions for an inspection of the gear set.
An ordinary planetary gear set is shown in the embodiment shown in FIGS. 4 and 5. This planetary gear set is surrounded by a housing comprising an upper part 27 and a lower part 28 which is provided with feet 20 for fastening purposes. The planetary gear set, whose design is of the familiar type, is supported in two longitudinal bearing carriers 25 and 26 arranged at a distance from one another. As shown in FIGS. 4 and 5, these longitudinal bearing carriers 25 and 26 are only fastened to the upper part of the housing 27 by means of screws 34.
As can be seen in FIGS. 4 and 5, the housing upper part 27 and the lower part 28 are provided with double walls 29, 30 and 31, 32 which form internal cavities filled with soundproofing material 17.
Stop bolts 23 are provided for the purposes of an inspection of the planetary gear set, which can be inserted in the bores 24 in a similar way to the design according to FIG. 2. In that way, the longitudinal bearing carriers 25 and 26 can be properly adjusted in the course of an inspection of the transmission, thus obviating the need for any subsequent adjustment.
The present invention concerns not only toothed gear transmissions but the housings of other mechanical equipment incorporating either rotary or reciprocating moving parts can also be configured according to the design which is the subject of the present invention, such as the bearing supports of electric motors, turbines, compressors, pumps or layshafts, should this be necessary in order to meet noise level regulations. The mounting feet 20 can be arranged for the unit to be suspended from the upper part of the housing 9 and/or 27, if necessary.
The mode of operation of the present invention will now be described in more detail: in the case of the spur gear transmission according to FIGS. 1-3, noise is mainly generated as a result of the meshing of the gear wheels 1 and 2 according to FIG. 2 at point 33. From here, the vibrational energy is transmitted over the structure of the gear wheels, shafts, bearings and bearing carriers to the housing walls, as shown by the wave lines in the drawings. It is here that the vibrations are damped in the arrangement according to the present invention, essentially as the result of three means:
The natural frequency is shifted between a non-soundproofed structure and a structure soundproofed according to the present invention.
The input impedance is raised as a result of the high structural stiffness resulting from the incorporation of double walls 13, 14, 15 and 16 and the heavy mass of soundproofing material with which they are filled.
Reduction of the structure-borne noise over a lengthy sound transmission path, as can be seen from the wave lines in FIG. 2, whereby the noise level is reduced by the internal friction of the soundproofing material. By the same token, a planetary gear transmission can also be provided with a lengthy sound transmission path, as is shown by the wave lines in FIG. 5.
A further improvement of soundproofing can be achieved by providing the bearings with internal damping, especially in the embodiment shown in FIGS. 1-3, where the lubrication film of the plain bearings 3 and 4 are treated in this way. The soundproofing can be even further enhanced by inserting an intermediate layer, such as a seal or similar, to provide increased frictional damping at the interfaces between the various components.
These are shown in FIGS. 2 and 5 as the coupling points in the structural noise flow path indicated in the drawings by a small circle, for example, at the interfaces between the bearings 3, 4 and the bearing carrier parts 5, 6, 5' and 6'; between the bearing carrier parts 5, 6, 5' and 6' and the upper part of the housing 9 and between the upper part of the housing 9 and the lower part 8, as well as between the housing 7 and its mounting base; and finally, by the application of one or several layers of soundproofing to the webs of the gear wheels 1 and 2.
Apart from its high level of soundproofing, the design according to the present invention offers the following additional advantages:
The precision-machined bearing bores in the bearing carriers 5 and 6, and/or 25 and 26, can be drilled separately without the housing. This simplifies this stage of the machining and saves costs.
In both embodiments, the complete gear set or just the upper part can be removed by removal of the upper part of the housing 9 or 27, whereby the presence of the recesses 21 provides excellent access to the screws 12.
The use of double wall construction provides the entire housing not only with high dynamic stiffness but gives it a high level of static rigidity as well. This enables deformation of the housing as a result of forces and torques impinging on it to be avoided and this makes for enhanced functional mechanical reliability of the unit.
The present invention thus provides the advantage of providing a low cost and effective way of substantially reducing the acoustic energy generated in an assembly comprising mechanical components in rotary or reciprocol movement, by incorporating heavy soundproofing inside the housing of the assembly. | 4y
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a national stage of PCT/RU2010/000560 filed Oct. 06, 2010 and based upon Russian Patent Application No. 2009136947 filed Oct. 07, 2009, under the International Convention.
FIELD OF THE INVENTION
[0002] The invention relates to metallurgy and can be used in the technology of production of steel products starting from steel melting and ending with output of rolled stock.
BACKGROUND OF THE INVENTION
[0003] Known in the art are steel production technological lines comprising interlinked steel melting crane and floor transport units, an out-of-furnace metallothermal section, and a casting section in the form of a continuous casting machine, in which steel teeming ladle cars are used as floor transport units (Certificate on useful model W 21198 of 02.10.2001, IPC C2105/28, and Certificate on useful model No. 84848 of 04.05.2009, IPC C2105/28).
[0004] These technological lines allow one to organize an integrated working cycle from melting of charging material till production of blanks.
[0005] The technological processes of melting, steel processing and steel teeming are difficult to be physically integrated in a single production plant. It is due to the fact that such installations as electrical melting furnaces, integrated processing plants, continuous casting stations and other metallurgical machines have been developed separately. In order to exclude breaks in the production structure, use is made of bridge cranes, steel-teeming ladles, intermediate ladles steel teeming ladle cars, etc. Their use compensates the breakdowns in the production cycle, but does not combine the installations into a single plant and creates problems in management of a steel-smelting enterprise.
[0006] Also known in the art are technological lines for production of metal rolled stock, comprising connected in series metallurgical assemblies of the steel melter and rolling mill interconnected transporting devices, units for processing the intermediate materials and units for treatment of intermediate products, in which the steel melter includes a melting furnace, out-of-furnace metal processing unit and a continuous casting station, wherein the melting furnace can be made in the form of a converter or an electric arc furnace (Certificate on useful model W-15673 of 07.09.2000, IPC B21 B1/4 6).
[0007] In this case transportation facilities are also used, in particular, steel teeming ladle cars that complicate the organisation of the process in an automatic mode thus reducing the production capacity.
[0008] Thus, the main disadvantage of the known plants is a significant loss of time and energy due to a long transportation path of the steel-teeming ladle between the electric furnace, the “furnace-ladle” machine, continuous casting machine (CCM) etc., an increase in the number of the working personnel servicing the bridge cranes, an increase of the danger at operation of transportation steel teeming ladles which are hanged up the hooks of the bridge cranes increase the cost of the main and auxiliary equipment due to applications of cranes and ladles, complexity in the organization of the process in an automatic mode.
SUMMARY OF THE INVENTION
[0009] The object of the claimed invention is to create a metallurgical complex allowing one to reduce loss of time and energy at work, to reduce the cost the equipment and personnel and to increase the reliability and safety of the whole complex.
[0010] This object is attained by creating a metallurgical complex including melting furnace, an out-of-furnace metal processing unit and a casting station, installed on technological platforms capable of receiving and transferring the molten metal with subsequent casting, characterized in that it is provided with three technological platforms installed one over another, the middle platform being capable of rotating about the central axis and is also provided with three identical lined containers situated in three positions at an angle of 120° to each other, the top platform being provided with means for melting metal and means for processing the melt capable of rising and lowering and installed on two adjacent lined containers to form steelmaking arc furnace positions and a melt processing unit positions, respectively, the casting station being mounted on the bottom platform in the immediate vicinity of the third position with a third lined container disposed therein.
[0011] The object of the invention is also attained due to the fact that the lined containers are capable of being inclined.
[0012] The object of the invention is also attained due to the fact that the metallurgical complex is provided with means for preheating the fusion mixture to be installed on a lined container disposed in the third position, which can be made in the form of a gas burner. The gas burner can be mounted on the lined container cover disposed in the third position.
[0013] The object of the invention is also attained due to the fact that the middle platform is installed on roller supports coupled to a rotary drive.
[0014] The object of the invention is also attained due to the fact that the metallurgical complex is provided with a matching device to control the rotation of the middle platform and movement by the devices for melting metal and melt processing.
[0015] The object of the invention is also attained due to the fact that the middle platform is made in the form of a ring, and metal melting and melt processing devices are made in the form of an electrode system and a lined dome.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention is illustrated with the drawings ( FIGS. 1-4 ).
[0017] FIG. 1 illustrates disposition of the main units of the metallurgical complex in a plan view.
[0018] FIG. 2 is a sectional view along the line A-A with the following units: a melting furnace and a lined container for preheating the fusion mixture arranged from left to right in the initial position.
[0019] FIG. 3 is a sectional view along the line A-A with the following units: a melting furnace and a lined container for preheating the fusion mixture in the working position;
[0020] FIG. 4 is a sectional view along the line A-A with the following units: a lined container for preheating the fusion mixture and a unit for integrated steel processing from left to right in the working position.
DESCRIPTION OF THE INVENTION
[0021] The metallurgical complex has three service levels and three working platforms. The top and platform 1 and a bottom platform 2 are stationary. The middle platform 3 is made in the form of a ring and is rotated by a drive (not shown) about the central axis 4 . This platform 3 is supported by three trunnion stations 5 and provided with three horizontal movement stabilizers 6 . Arranged on this platform 3 at an angle of 120° to each other are three lined containers 7 , 8 , 9 made capable of inclination.
[0022] Their location is fixed at three positions I, II, III at an angle of 120°. At a starting point the container 9 is located in plan on the vertical C-C at the lower part of the circle ( FIG. 1 ), and the first (container 7 ) and the second (container 8 ) parts are disposed at an angle of 120° to the left and to the right of the vertical C-C respectively. Arranged on the top stationary platform 1 are two portal cranes 10 and 11 with mechanisms for lifting electrodes 12 and 13 and domes 14 and 15 and mechanisms to control the electrodes 12 and 13 , two furnace transformers 16 and 17 with a system to supply electric power to the electrodes 12 and 13 ( FIGS. 2-4 ).
[0023] Installed in position III is a console crane 18 with a cover 19 , on which a gas burner 20 is secured. In this position the entire volume of melt is poured from the lined container into a metal receiver 21 of a steel pouring station 22 of a horizontal continuous casting machine or a machine with a low casting radius which are installed on the bottom stationary platform 2 ( FIGS. 2-4 ).
[0024] FIG. 1 illustrates a layout of the main technological equipment of the metallurgical complex. The top platform 1 made in the form of a semicircle overlapping positions I and II supports the portal crane 10 of an arc steel melting furnace SMF, a portal crane 11 of the integrated steel processing plant (SPP), the furnace transformer 16 , the SPP transformer 17 .
[0025] The platform 3 rests on three trunnion stations 5 and is made of modular steel structures ( FIGS. 2-4 ). To reduce the weight of the platform, apertures are made therein. The platform is rotated by a mechanical drive (not shown in the drawing).
[0026] Arranged on the bottom platform 2 at the zero mark is the steel pouring station 22 of the horizontal continuous casting machine with a metal receiver 21 and a support 23 for the console crane 18 .
[0027] Operation of the Metallurgical Complex
[0028] The metallurgical complex operates as follows. In the zero cycle ( FIG. 2 ) i.e. at the beginning of operation of the complex, the lined container 9 being in position III is charged with a fusion mixture, closed with the cover 19 , and the gas burner 20 is switched on to preheat the fusion mixture. The containers 7 and 8 are not yet loaded. After the fusion mixture in the container 9 has been heated up to a preset temperature, the heating is stopped, the cover 19 with the burner 20 is lifted, and the lined container 9 is transferred to position I by turning the platform 3 around 120°. In so doing the containers 7 and 8 also move and take positions II and III.
[0029] Then in position I the container 9 is covered with the portal crane 10 hanged up on chains, the dome 14 and electrodes 12 , the SMF power supply is switched on and the preheated fusion mixture is melting down ( FIG. 3 ). In so doing the container 7 in position II is not yet filled. Within the same cycle the container 8 is moved to position III, loaded with a portion of the fusion mixture, the cover 19 is lowered and the gas burner 20 is switched on to heat the new portion of the fusion mixture in the container 8 ( FIG. 3 ). This takes place simultaneously with melting the first portion of the fusion mixture in position I of the container 9 .
[0030] When in position I the melt in the container 9 is ready and in position III the fusion mixture in the container 8 is hot, the SMF and the burner 20 are switched off and the dome 14 with electrodes 12 and the cover 19 and the burner 20 is lifted up.
[0031] Then the platform 3 is again turned around 120°. After that the containers 7 , 8 , 9 are moved to positions III, I, II respectively. Then the dome 14 with the electrodes 12 is again lowered in position I and close the container 8 , the dome 15 with electrodes 13 is set in position II and close the container 9 , and in position III the cover 19 with the burner 20 covers the container 7 preloaded with the fusion mixture.
[0032] After that the power supply is connected to the SMF, the SPP to the burner and the metal in a SMF is melted in position I, the processing of the molten metal in the SPP is effected in position II, and the fusion mixture preheating is made in position III. After the next cycle, in which the platform is turned through the following 120° and the container 9 with the first portion of metal processed in the SPP arrives, it is discharged into the metal receiver 21 of the pouring station 22 of the horizontal continuous casting machine for producing blanks. Then fusion mixture is loaded again and the following cycle of preheating is started in position III, the melting in position I, the metal processing in position II and the metal pouring with subsequent loading of the fusion mixture for preheating in position III. After that all operations on preheating the fusion mixture, its melting, integrated processing and ingot pouring are made in positions III, I and II respectively. FIG. 4 Illustrates the working moment of preheating the fusion mixture in the container 8 in position III and integrated processing of the molten metal in the container 7 in position II.
[0033] The slag removal is made by draining the metal processed in position II through the apertures 24 into the slag cup installed on the bottom platform 1 . The slag cup is driven away by a special tractor or in another way.
[0034] The time of each cycle is calculated so that simultaneously with melting the fusion mixture in position I, the fusion mixture in position III would be already preheated to a required temperature, and the metal arrived at the SPP for processing would be already processed in position II. In this case all containers will be synchronously turned around for respective 120°. In so doing the time of pouring the metal, loading the fusion mixture and its preheating in position III strictly corresponds to the time of fusion and metal processing in positions I and II.
[0035] The control the process of turning the platform 3 and lowering and rising the domes and covers is performed by a matching device associated with the system of automatic control of the preheating, melting and processing processes (not shown in the drawing). This device includes a mechanism for turning the platform 3 after a preset time and generates a signal on rising or lowering of the domes, switching on/off the power supply for carrying out the processes of preheating the fusion mixture and steel melting and processing in positions I, II, III.
[0036] Thus, making the working platform 3 with a possibility of rotation provides transfer of the melting containers 7 , 8 , 9 under a cyclic schedule from one position to another through a certain time period during which a definite technological process is carried out in each container.
[0037] For coordination of the working cycles of the SMF, the steel processing plant (SPP) and the continuous casting machine their working capacity must be the same. The cycle time should correspond to the SMF operating time under load, the time of pouring of the molten steel from the container. To reduce the operating time of the SMF under load, in position I the fusion mixture is preheating in one of the three containers. Thus, at the initial step in position III the fusion mixture is additionally heated, in position I the container performs the SMF function, in the third position II the container performs the SPP function. The volume of the melting containers is designed for loading a single charge and conducting the process without additional charging. The control is performed from a single control panel.
INDUSTRIAL APPLICABILITY
[0038] Due to a compact design and availability of the rotating platform with melting containers, as well as due to a discharge of the whole melt into the metal receiver of the melting machine, this metallurgical complex has no need in steel-teeming ladles and bridge cranes.
[0039] In this case it is possible to reduce a loss of time, energy consumption and material cost due to the absence of steel-teeming ladles and bridge cranes and a necessity of their servicing, as well as a reduction of the cost of the main and auxiliary equipment due to the exclusions of cranes and ladles, a continuous operating cycle is realizable. The claimed invention will find wide application in the iron and steel industry at construction of minifactories for production of metal rolled stock. | 4y
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BACKGROUND OF THE DISCLOSURE
[0001] 1. Field of Disclosure
[0002] The present disclosure relates generally to the field of combustion furnaces and methods of use, and more specifically to improved submerged combustion melters and methods of use in producing molten glass from recycled glass mat and other rolled glass materials, such as wound rovings of continuous glass filament.
[0003] 2. Related Art
[0004] Glass mat products such as fiber glass and mat and insulation mat are characterized by a nonwoven mat of glass fibers held together with a binder. Recycling or reclamation of glass mat products has been disclosed in and practiced previously. Many of these disclosed methods involve crushing the glass mat to a maximum fiber or particle size prior to re-melting. Other processes involve a heating step prior to grinding whereby the binder is first burned off without melting the glass fibers. In older processes the binders were typically desired to be removed prior to re-melting because the remnants of the binders may cause production of unsatisfactory glass products.
[0005] Submerged combustion has been proposed in several patents for application in commercial glass melting, including U.S. Pat. Nos. 4,539,034; 3,170,781; 3,237,929; 3,260,587; 3,606,825; 3,627,504; 3,738,792; 3,764,287; 6,460,376; 6,739,152; 6,857,999; 6,883,349; 7,273,583; 7,428,827; 7,448,231; 7,565,819, and 7,624,595; published U.S. Pat. Application numbers 2004/0168474; 2004/0224833; 2007/0212546; 2006/0000239; 2002/0162358; 2009/0042709; 2008/0256981; 2007/0122332; 2004/0168474; 2004/0224833; 2007/0212546; and 2010/0064732; and published PCT patent application WO/2009/091558, all of which are incorporated herein by reference in their entireties. In submerged combustion glass melting, the combustion gases are injected beneath the surface of the molten glass and rise upward through the melt. The glass is heated at a higher efficiency via the intimate contact with the combustion gases. However, submerged combustion burners have not heretofore been used to recycle or reclamate glass mat products without first crushing the mat products to reduce the size of the glass fibers.
[0006] U.S. Pat. No. 4,397,692 discloses methods and apparatus for the reclamation of inorganic fibers from waste continuous strips of inorganic fibers. The '692 patent mentions another, previous recapture technique is to feed the recaptured fibers directly into the melting furnace with virgin glass batch. The difficulty with this approach, according to the '692 patentees, is that a major amount of the cost of the fiber is not in the material but, in the cost of production and, by melting the fibers, that amount is lost. In addition, the cost of processing the fibers for feeding to a batch furnace is equal to or greater than the cost of the batch it replaces, making this process economically unattractive. According to the Abstract of the '692 patent, a binding agent, such as an organic binder, must be removed before the fibers can be reused or further processed. One or more layers of continuous strips are conveyed to a heating zone where the strips are supported along a predetermined path as a heating fluid is drawn rapidly through the strips to decompose the binder. Unfortunately, the '692 patent suggests that in the case where binder is still present on the fibers in unacceptable levels, these non-reclaimable fibers may be dumped for subsequent disposal. This practice is now unacceptable, due to the lack of landfill space available, and due to the justifiably increased concern for the environment. The '692 patent does not disclose, teach or suggest roll-feeding of fiber glass mat scrap or rovings, or folding shoes, or nip rollers being used to feed fiberglass mat scrap to a melter.
[0007] U.S. Pat. No. 4,422,862 describes a process for feeding scrap glass to a glass melting furnace. The scrap glass is fed onto a blanket of batch in the furnace so that organics are burned off before the scrap melts. The scrap glass is either first hammermilled or crushed before it is fed to the glass melting furnace, or enters the furnace in the form of fluffy, fine textured scrap that floats on the batch blanket. There is no teaching or suggestion of roll-feeding, or folding shoes, or of nip rollers being used to feed the scrap to the melter. There is disclosed use of a conveyor belt, but the patentee states “In FIG. 2 , scrap glass is manually fed onto belt conveyor 12 at a controlled rate. The cullet glass previously has been processed through a crusher (not shown).” Clearly, crushing is involved, as the patentee states “the crushing advantages are fluffy fine textured scrap that floats on the batch cover allowing good penetration and binder burn-off by furnace gases.”
[0008] U.S. Pat. No. 4,432,780 discloses a method of reclaiming chemically coated glass scrap. The scrap is introduced into the oxidizing atmosphere of a hydrocarbon-fuel fired glass melting furnace. Some of the glass is melted with the unmelted portion being melted with the glass batch as it moves through the furnace. The patentees state that “The scrap glass can be introduced into the furnace in any suitable form. Preferably, it will be introduced in particulate form up to about 1¼ inch screen size by means of a blowing wool machine, one or more machines being used depending upon the quantity of scrap glass being introduced.” Despite the broad introductory statement that “the scrap glass can be introduced in any suitable form”, the particulate form is the only form that is disclosed. Thus, this patent fails to disclose, teach, or suggest roll-feeding, or folding shoes, or of nip rollers being used to feed scrap to the melter.
[0009] U.S. Pat. No. 4,309,204 discloses a process and apparatus for remelting scrap glass fibers. The removal of binder and remelting of the scrap are carried out in one operation, and the resulting molten scrap fibers are fed directly into a conventional glass melting furnace. Granular raw glass batch also is fed into the glass melting furnace. FIGS. 1 and 2 of the '204 patent show a glass feeder feeding glass strands to a melter through rotating shaft feeders. Thus, this patent fails to disclose, teach, or suggest roll-feeding of fiber glass mat scrap or rovings, or folding shoes, or nip rollers being used to feed fiberglass mat scrap to a melter.
[0010] JP 2000351633 is another example method and apparatus for recycling fiber glass waste. The reference discloses use of a burner to feed waste glass fiber to a glass melting tank furnace. The recycling apparatus is provided with a hopper for storing waste glass fiber cut to proper size and a constant-rate discharging apparatus to discharge the waste material at a constant rate. This reference fails to disclose, teach, or suggest roll-feeding of fiber glass mat scrap or rovings, or folding shoes, or nip rollers being used to feed fiberglass mat scrap to a melter.
[0011] JP 2002120224 discloses a method for recycling glass fiber-reinforced thermoplastic resin characterized by feeding the glass fiber-reinforced thermoplastic resin for recycling to a vessel wherein a non-recycled thermoplastic resin is under melted condition. Thus, the approach here is not to feed the fiber glass reinforced waste into a glass tank furnace, but into a tank of molten thermoplastic resin. This reference therefore fails to disclose, teach, or suggest roll-feeding of fiber glass mat scrap or rovings, or folding shoes, or nip rollers being used to feed fiberglass mat scrap to a glass tank melter.
[0012] It would be an advance in glass mat recycling to develop methods and apparatus for recycling and/or reclaiming glass mat and similar items, such as wound roving of continuous glass filament, that avoid the significant processing needed to shred such materials and/or mill it into a fine powder for re-melting, while taking advantage of the efficiency of submerged combustion burners, to increase melter throughput and produce high quality molten glass.
SUMMARY
[0013] In accordance with the present disclosure, methods and apparatus for practicing the methods are described for recycling rolled glass materials, such as glass mat and wound rovings, that reduce or eliminate the need to shred or crush such glass materials before feeding same into a glass tank melter, and that take advantage of the efficiency of submerged combustion burners.
[0014] Various terms are used throughout this disclosure. A “web” refers to woven and nonwoven mats of glass fiber, and is typically, but not necessarily, rolled up into a roll. “Mat” as used herein refers to lofted and non-lofted (essentially flat) nonwoven glass fiber articles. An example of a lofted nonwoven is glass fiber insulation batting, while an example of a non-lofted nonwoven is E-Glass mat as is commonly used in roofing shingles and other high-performance applications. “Roving” as used herein refers to a plurality of filaments of glass fiber substantially parallel to a major axis of the roving. “Scrap” is a general term for glass fiber mat pieces, rovings, or other rolls of material that, for one reason or another, is off-specification or trimmed from a larger web of useable material, and would otherwise be landfilled, but for the teaching of the present disclosure. “Submerged” as used herein means that combustion gases emanate from burners under the level of the molten glass; the burners may be floor-mounted, wall-mounted, or in melter embodiments comprising more than one submerged combustion burner, any combination thereof (for example, two floor mounted burners and one wall mounted burner). As used herein the term “combustion gases” means substantially gaseous mixtures of combusted fuel, any excess oxidant, and combustion products, such as oxides of carbon (such as carbon monoxide, carbon dioxide), oxides of nitrogen, oxides of sulfur, and water. Combustion products may include liquids and solids, for example soot and unburned liquid fuels. “Oxidant” as used herein includes air and gases having the same molar concentration of oxygen as air, oxygen-enriched air (air having oxygen concentration of oxygen greater than 21 mole percent), and “pure” oxygen, such as industrial grade oxygen, food grade oxygen, and cryogenic oxygen. Oxygen-enriched air may have 50 mole percent or more oxygen, and in certain embodiments may be 90 mole percent or more oxygen. Oxidants may be supplied from a pipeline, cylinders, storage facility, cryogenic air separation unit, membrane permeation separator, or adsorption unit.
[0015] A first aspect of this disclosure is a method comprising:
a) providing a source of glass mat or wound roving; and b) routing the glass mat or wound roving at a substantially consistent feed rate into a submerged combustion melter and melting the glass mat or roving.
[0018] As used herein the phrase “substantially consistent feed rate” means that the rate of glass mat or roving entering the melter is, in certain embodiments, constant, but may in certain embodiments vary from constant by a small percentage, for example +/−1 percent, or +/−5 percent, or +/−10 percent. In certain embodiments, the mass of a particular web of glass mat or roving per unit of length may not vary significantly as the web or roving is fed into the melter, and in these embodiments the web or roving feed rate (unit of length per unit of time) may not need to vary significantly in order to maintain a substantially consistent feed rate (mass per unit of time) of glass mat or roving into the melter. In certain other embodiments, the mass of a particular web of glass mat or roving may vary with length (for example the web or rovings may decrease in mass as the web or rovings is/are unwound from a roll), and in these instances the linear speed of the web or rovings may be increased so that the feed rate of material into the melter remains substantially consistent over time. In certain methods and apparatus of this disclosure the substantially consistent feed rate may be accomplished by unwinding a web of the glass mat or one or more wound rovings off of one or more rolls using a combination of an unwind system and a pair of powered nip rolls, conveyers, or other arrangement. In certain embodiments, the powered nip rolls could be supplemented with or replaced by a nip compression conveyor, or opposed conveyors compressing the product to accomplish the same aim. To avoid repetition, the term “powered nip rolls” will be used herein, with the understanding that these other arrangements could be used just as well. In certain embodiments, the mat or rovings may be chopped downstream or integral to the nip rollers and/or conveyors and prior to entering the glass tank furnace.
[0019] The source of glass mat may be selected from the group consisting of nonwovens and woven materials. Nonwovens may be lofty or non-lofty. High loft is thick and fluffy, low loft is thin and dense. The higher the loft, the better the insulation characteristic.
[0020] In certain embodiments, the nonwoven is a non-lofty mat, such as a mat of E-Glass fibers. Such mats are often used in constructing roofing shingles.
[0021] In certain embodiments, the method comprises providing a web of substantially continuous glass fibers bound together randomly at points where adjacent fibers touch using a binder.
[0022] In certain embodiments, the glass mat and/or rovings enter the submerged combustion melter through a slot in the melter and then directly into molten glass within the melter.
[0023] In certain embodiments, more particular to embodiments where glass mat is processed may be rout the glass mat through a forming or converting device prior to entering the powered nip rolls so that the glass mat fits through the slot. One example of such a forming or converting device is a folding device. Another example of a forming device is a cutting or slitting device wherein the glass mat is cut to width prior to entering the powered nip rolls so that the glass mat fits through the slot.
[0024] In certain embodiments, the unwinding of the roll comprises changing rolls on the fly, which may comprise splicing a first web unwinding from a first roll to a second web unwinding from a second roll.
[0025] In certain methods the melting comprises at least one burner directing combustion products into a melting zone under a level of molten glass in the zone.
[0026] In certain methods at least some heat used for the melting of the glass mat and/or roving comprises heat from combustion of at least some of the binder.
[0027] In certain methods the melter is operated at a pressure less than atmospheric pressure. These methods may ensure that any combustion products generated during the melting of the glass remain in the system and do not escape through the feed slot.
[0028] Another aspect of this disclosure are apparatus comprising:
a) a source of rolled glass mat or wound roving material; b) a submerged combustion melter having a slot for feeding the glass mat or wound roving material into the melter and one or more submerged combustion burners; and c) a pair of powered nip rolls for feeding the glass mat or wound roving material into the melter at a substantially consistent rate.
[0032] In certain apparatus embodiments, the apparatus comprises an unwind subsystem for unwinding the rolled glass mat or wound roving in combination with the powered nip rolls. Certain embodiments include a glass mat forming device positioned prior to the powered nip rolls so that the glass mat is formed to fit through the slot. Folding, cutting and/or slitting the mat to an acceptable width to fit the mat through the slot are examples of forming devices. Two or more functions of folding, cutting, and the like may be combined in one forming device.
[0033] Certain apparatus embodiments of this disclosure may include melters comprising fluid-cooled panels, wherein the slot is covered and integral with a fluid-cooled panel of a wall of the melter. In certain other embodiments, the slot may be integral with an exhaust port or roof of the melter. In certain embodiments, the slot may comprise one or more hinged doors or panels. In certain other embodiments the slot may comprise one or more sliding doors or panels. Certain embodiments may comprise both hinged and sliding doors or panels. The hinged and sliding doors may be water cooled, or cooled by other fluids.
[0034] In practice, the submerged combustion melter may include one or more submerged combustion burners comprising one or more oxy-fuel combustion burners.
[0035] In all apparatus embodiments the sources of oxidant and fuel may be one or more conduits, pipelines, storage facility, cylinders, or, in the case of oxidant, ambient air. Secondary and tertiary oxidants, if used may be supplied from a pipeline, cylinder, storage facility, cryogenic air separation unit, membrane permeation separator, or adsorption unit such as a vacuum swing adsorption unit.
[0036] Certain embodiments may comprise using oxygen-enriched air as the primary oxidant, the fuel is a gaseous fuel, the gaseous fuel being selected from methane, natural gas, liquefied natural gas, propane, carbon monoxide, hydrogen, steam-reformed natural gas, atomized oil or mixtures thereof, and the oxygen-enriched air comprising at least 90 mole percent oxygen. In certain embodiments the oxygen may be injected into an intermediate mixture upstream of a combustion chamber of a burner, while in other embodiments the oxygen may be injected into the combustion chamber.
[0037] Apparatus and process embodiments of the disclosure may be controlled by one or more controllers. For example, burner combustion (flame) temperature may be controlled by monitoring one or more parameters selected from velocity of the fuel, velocity of the primary oxidant, mass and/or volume flow rate of the fuel, mass and/or volume flow rate of the primary oxidant, energy content of the fuel, temperature of the fuel as it enters the burner, temperature of the primary oxidant as it enters the burner, temperature of the effluent, pressure of the primary oxidant entering the burner, humidity of the oxidant, burner geometry, combustion ratio, and combinations thereof. Apparatus and processes of this disclosure may also measure and/or monitor feed rate of glass mat or wound roving, mass of glass mat or wound roving per unit length, web or roving linear speed, and combinations thereof, and use these measurements for control purposes. Exemplary apparatus and methods of the disclosure comprise a combustion controller which receives one or more input parameters selected from velocity of the fuel, velocity of the primary oxidant, mass and/or volume flow rate of the fuel, mass and/or volume flow rate of the primary oxidant, energy content of the fuel, temperature of the fuel as it enters the burner, temperature of the primary oxidant as it enters the burner, pressure of the oxidant entering the burner, humidity of the oxidant, burner geometry, oxidation ratio, temperature of the effluent and combinations thereof, and employs a control algorithm to control combustion temperature based on one or more of these input parameters.
[0038] Apparatus and methods of the disclosure will become more apparent upon review of the brief description of the drawings, the detailed description of the disclosure, and the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] The manner in which the objectives of the disclosure and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
[0040] FIGS. 1 and 2 are schematic side elevation views, with some parts broken away, of two apparatus and process embodiments in accordance with the present disclosure;
[0041] FIG. 3 is one embodiment of a process control schematic diagram for the apparatus and processes of FIGS. 1 and 2 ; and
[0042] FIGS. 4-8 illustrate perspective and side elevation ( FIG. 6 ) views of four embodiments of slots useful in the apparatus and processes in the present disclosure.
[0043] It is to be noted, however, that the appended drawings are not to scale and illustrate only typical embodiments of this disclosure, and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.
DETAILED DESCRIPTION
[0044] In the following description, numerous details are set forth to provide an understanding of various apparatus and process embodiments in accordance with the present disclosure. However, it will be understood by those skilled in the art that the apparatus and processes of using same may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible which are nevertheless considered within the appended claims.
[0045] Referring now to the figures, FIGS. 1 and 2 are schematic side elevation views, with some parts broken away, of two apparatus and process embodiments in accordance with the present disclosure. The same numerals are used for the same or similar features in the various figures. In the views illustrated in FIGS. 1 and 2 , it will be understood in each case that the figures are schematic in nature, and certain conventional features are not illustrated in order to illustrate more clearly the key features of each embodiment.
[0046] Embodiment 100 of FIG. 1 comprises a melter 2 , which may be any of the currently known submerged combustion melter designs as exemplified in the patent documents previously incorporated hereby reference in the Background of the present disclosure, or may be one of those described in assignee's currently pending patent application Ser. No. 12/817,754, filed Jun. 17, 2010, incorporated herein by reference. Melter 2 includes a roof 3 , side walls 5 , a floor 7 , one or more submerged combustion burners 8 , an exhaust chute 12 , one or more molten glass outlets 28 (only one being illustrated), and fluid-cooled panels 30 comprising some or all of side walls 5 . Molten glass 4 is sometimes referred to herein simply as the “melt”, and has a level 6 in melter 2 . Melter 2 is typically supported on a plant floor 10 .
[0047] In accordance with the present disclosure, first embodiment 100 comprises one or more roll stands 14 (only one being illustrated), which in turn supports one or more rolls 16 of glass mat. Roll stand 14 connects to roll 16 though an unwind driver and brake combination 15 , which are known in the roll-handling art. Roll stand 14 is supported by a plant floor 10 ′, which may be the same or different floor as floor 10 which supports melter 2 (in other words, roll stand 14 may be supported by a second floor of a plant or facility, although this is not necessary to practice the methods and apparatus of this disclosure).
[0048] Other components of embodiment 100 include a glass mat forming device 20 , a set of powered nip rolls 24 , and a glass mat feed slot 26 . In certain embodiments, as mentioned previously, powered nip rolls 24 may be supplemented with or replaced by a nip compression conveyor, or opposed conveyors compressing the product to accomplish the same aim. Forming device 20 is optional, but when present, may be selected from any one or more devices providing one or more functions, for example, but not limited to cutting, slitting (cutting in longitudinal direction), folding, shaping, compacting, pressing, coating, spraying, heating, cooling, and the like, and combinations thereof. An example of a single device providing two functions would be a device providing both heating and folding. The powered nip rolls 24 may also provide some degree of heating, cooling, compressing, and other forming function or functions, although their primary function is to draw the glass mat web off of roll 16 , in conjunction with unwind driver/brake combination 15 . In certain embodiments, as mentioned previously, the powered nip rolls may include cutting knives or other cutting components to cut or chop the mat (or roving, in those embodiments processing rovings) into smaller length pieces prior to entering melter 2 .
[0049] In operation of embodiment 100 of FIG. 1 , glass mat 18 is unwound from a roll of glass mat in conjunction with powered nip rolls 24 . Glass mat 18 may be, for example, but not limited to glass mat scrap. Glass mat 18 optionally is routed through one or more forming devices 20 to form a formed glass mat 22 . Powered nip rolls 24 then route formed glass mat 22 through feed slot 26 , which feeds the glass mat directly into the molten glass 4 . Glass mat 22 may be fed into molten glass 4 from above the level 6 , as illustrated in embodiment 100 of FIG. 1 . Alternatively, in certain embodiments, all or a portion of glass mat 22 may be routed under the level 6 of molten glass 4 . Whether the glass mat is fed directly to molten glass 4 through level 6 , or all or a portion is fed under level 6 depends on factors such as the configuration and pull rate of melter 2 .
[0050] Referring now to FIG. 2 , embodiment 200 is illustrated. In embodiment 200 , melter 2 has a slightly different exhaust chute 12 configuration, and in embodiments such as this, it may be more convenient to position feed slot 26 in exhaust chute 12 and feed glass mat 22 (or wound roving) through feed slot 26 and exhaust chute 12 , as illustrated. A dashed, phantom portion of feed slot 26 is illustrated as an extension, which may be present in certain embodiments to ensure that glass mat web 22 enters molten glass 4 in a desired location. Any location is possible, but for the limitation that glass mat is molten before leaving molten glass outlet 28 . Also provided in this embodiment is a glass batch feeder 32 . Glass batch feeders are well-known in this art and require no further explanation. A glass mat web cutting device 21 is provided in this embodiment.
[0051] FIG. 3 is a schematic diagram of one embodiment of a process control scheme for the apparatus and processes of FIGS. 1 and 2 . A master process controller 300 may be configured to provide any number of control logics, including feedback control, feed-forward control, cascade control, and the like. The disclosure is not limited to a single master process controller 300 , as any combination of controllers could be used. The controller may be selected from PI controllers, PID controllers (including any known or reasonably foreseeable variations of these), and computes a residual equal to a difference between one or more measured values 36 , 38 , 40 , 42 , 44 , 46 , 48 , 50 , 52 , 54 , 56 , 50 , and 60 and one or more set points 34 , for example feed rate (mass/time) of glass mat or rovings into melter 2 , to produce one or more outputs 62 , 64 , 66 , 68 , and 70 to one or more control elements. The controller 300 may compute the residual continuously or non-continuously. Other possible implementations of the disclosure are those wherein the controller comprises more specialized control strategies, such as strategies selected from internal feedback loops, model predictive control, neural networks, and Kalman filtering techniques. In FIG. 3 , the lines numbered 36 , 38 , 40 , 42 , 44 , 46 , 48 , 50 , 52 , 54 , 56 , 50 , and 60 may represent sensors, for example sensors for the following parameters, which are merely exemplary examples:
36 =weight of mat or roving (mass/length); 38 =unwind speed of mat or roving (length/time); 40 =temperature of melt 4 ; 42 =temperature of fuel entering a burner; 44 =temperature of oxidant entering a burner; 46 =temperature of exhaust form melter; 48 =level of melt in melter; 50 =mass flow rate of fuel entering burner; 52 =mass flow rate of primary oxidant entering burner; 54 =energy content of fuel; 56 =humidity of primary oxidant; 58 =width of glass mat web or roving from roll; 60 =flow rate of melt out of melter;
[0065] The lines numbered 62 , 64 , 66 , 68 , and 70 may represent control signals and actuators, respectively, for outputs for the following parameters, which are merely exemplary:
62 =corrected mass flow rate of fuel to burners; 64 =corrected mass flow of oxidant to burners; 66 =corrected speed of unwinding of roll of glass mat or roving; 68 =corrected nip roll speed; and 70 =corrected flow of melt out of melter.
[0071] Other parameters may be included as inputs, such as weight of roll, burner geometry, and combustion ratio.
[0072] The term “control”, used as a transitive verb, means to verify or regulate by comparing with a standard or desired value. Control may be closed loop, feedback, feed-forward, cascade, model predictive, adaptive, heuristic and combinations thereof. The term “controller” means a device at least capable of accepting input from sensors and meters in real time or near-real time, and sending commands directly to burner control elements, and/or to local devices associated with burner control elements and glass mat feeding devices able to accept commands. A controller may also be capable of accepting input from human operators; accessing databases, such as relational databases; sending data to and accessing data in databases, data warehouses or data marts; and sending information to and accepting input from a display device readable by a human. A controller may also interface with or have integrated therewith one or more software application modules, and may supervise interaction between databases and one or more software application modules.
[0073] The controller may utilize Model Predictive Control (MPC). MPC is an advanced multivariable control method for use in multiple input/multiple output (MIMO) systems. An overview of industrial Model Predictive Control can be found on the Internet, which will direct the reader to many sources, including textbooks. MPC computes a sequence of manipulated variable adjustments in order to optimise the future behavior of the process in question. At each control time k, MPC solves a dynamic optimization problem using a model of the controlled system, so as to optimize future behavior (at time k+1, k+2 . . . k+n) over a prediction horizon n. This is again performed at time k+1, k+2 . . . MPC may use any derived objective function, such as Quadratic Performance Objective, and the like, including weighting functions of manipulated variables and measurements. Dynamics of the process and/or system to be controlled are described in an explicit model of the process and/or system, which may be obtained for example by mathematical modeling, or estimated from test data of the real process and/or system.
[0074] FIGS. 4-8 illustrate non-limiting examples of slots useful in apparatus and methods of this disclosure. FIG. 4 illustrates a perspective view of embodiment 80 , having a single door or panel 82 which swings open vertically away from melter 2 when it is desired to feed a non-woven 22 into melter 2 for recycling. Door or panel 82 is secured to melter 2 by a hinge 84 which ruins along the bottom edge of door 82 , and handles 86 , 87 are provided in this embodiment to allow personnel to open and close door 82 . Alternatively, or in addition, a mechanical opening and closing mechanism may be provided, such as that discussed in reference to FIG. 7 , or equivalent thereof.
[0075] FIG. 5 illustrates a perspective view of another embodiment 90 within this disclosure, this embodiment comprising a pair of horizontally opening doors 92 , 94 , also featuring hinged connections 93 , 95 , connecting the doors to melter 2 , respectively.
[0076] FIG. 6 illustrates a side elevation view of an embodiment 110 of a vertical sliding door or panel 112 which may function as a slot in accordance with the present disclosure, where panel 112 is integral with a fluid-cooled wall 30 of melter 2 . Sliding door or panel 112 may be held open or closed at a variety of vertical positions, for example using a locking device, clamp or similar mechanism 114 . This would allow nonwovens of various thicknesses to be processed. Sliding door or panel 112 may itself be fluid-cooled.
[0077] FIG. 7 illustrates a perspective view of yet another embodiment 120 of a slot useful in the apparatus and methods of this disclosure. Embodiment 120 comprises a vertically sliding door or panel 122 , and a horizontally sliding door or panel 124 . Vertical door or panel 122 slides in vertical guides 126 , 128 , while horizontal door or panel 124 slides in guides 129 . In order to open and close, or adjust the height of vertical door or panel 122 , handles 130 , 132 may be provided. Alternatively, or in addition thereto, a pneumatic, hydraulic, or electronic actuator 134 may be provided. A similar actuator 136 may be provided to open, close, or adjust width of the slot. Embodiment 120 allows adjustment of either height, width, or both height and width to accommodate various stock sizes (not shown).
[0078] FIG. 8 illustrates a perspective view of yet another embodiment 150 of a slot useful in the apparatus and methods of this disclosure for melting one or more rovings 152 of glass fiber. In the case of rovings 152 , the adjustable vertically sliding door or panel 122 and horizontally sliding door or panel 124 may be adjusted to accommodate different number and/or sizes of rovings.
[0079] Those having ordinary skill in this art will appreciate that there are many possible variations of the slot openings described herein, and will be able to devise alternatives and improvements to those described herein that are nevertheless considered to be within the claims of the present patent. For example, in the embodiments illustrated in FIGS. 7 and 8 , a second vertical sliding door or panel could be provided, moving from the bottom of the slot up to meet the one illustrated, or this upwardly moving door or panel could completely replace the one illustrated. Similarly, a second horizontal sliding door or panel could be provided, sliding in from the right-hand side of the slot, or this sliding door or panel could replace the horizontal one illustrated. Sets of ceramic or metallic rollers could be provided to supplement the guides, or completely replace the guides.
[0080] Submerged combustion melters useful in the practice of the methods and apparatus of this description may take any number of forms, including those described n assignee's co-pending application Ser. No. 12/817,754, previously incorporated herein by reference, which describes sidewalls forming an expanding melting zone formed by a first trapezoidal region, and a narrowing melting zone formed by a second trapezoidal region, wherein a common base between the trapezoid defines the location of the maximum width of the melter.
[0081] Another important feature of apparatus of this disclosure is the provision of submerged combustion burners 8 in melter 2 . In embodiments 100 and 200 , burners 8 are floor-mounted burners. In certain embodiments, the burners may be positioned in rows substantially perpendicular to the longitudinal axis (in the melt flow direction) of melter 2 . In certain embodiments, burners 8 are positioned to emit combustion products into molten glass in the melting zone of melter 2 in a fashion so that the gases penetrate the melt generally perpendicularly to the floor. In other embodiments, one or more burners 8 may emit combustion products into the melt at an angle to the floor, as taught in assignee's pending Ser. No. 12/817,754.
[0082] Melters useful in apparatus in accordance with the present disclosure may also comprise one or more wall-mounted submerged combustion burners, and/or one or more roof-mounted burners. Roof-mounted burners may be useful to pre-heat the melter apparatus melting zone, and serve as ignition sources for one or more submerged combustion burners 8 . Melter apparatus having only wall-mounted, submerged-combustion burners are also considered within the present disclosure. Roof-mounted burners may be oxy-fuel burners, but as they are only used in certain situations, are more likely to be air/fuel burners. Most often they would be shut-off after pre-heating the melter and/or after starting one or more submerged combustion burners 8 . In certain embodiments, if there is a possibility of carryover of particles to the exhaust, one or more roof-mounted burners could be used to form a curtain to prevent particulate carryover. In certain embodiments, all submerged combustion burners 8 are oxy/fuel burners (where “oxy” means oxygen, or oxygen-enriched air, as described earlier), but this is not necessarily so in all embodiments; some or all of the submerged combustion burners may be air/fuel burners. Furthermore, heating may be supplemented by electrical heating in certain embodiments, in certain melter zones. In certain embodiments the oxy-fuel burners may comprise one or more submerged combustion burners each having co-axial fuel and oxidant tubes forming an annular space therebetween, wherein the outer tube extends beyond the end of the inner tube, as taught in U.S. Pat. No. 7,273,583, incorporated herein by reference. Burners 8 may be flush-mounted with floor 7 in certain embodiments. In other embodiments, such as disclosed in the '583 patent, a portion of one or more of the burners 8 may extend slightly into the melt above floor 7 .
[0083] In certain embodiments, melter side walls 5 may have a free-flowing form, devoid of angles. In certain other embodiments, side walls 5 may be configured so that an intermediate location may comprise an intermediate region of melter 2 having constant width, extending from a first trapezoidal region to the beginning of a narrowing melting region. Other embodiments of suitable melters are described in the above-mentioned '754 application.
[0084] As mentioned herein, useful melters may include refractory fluid-cooled panels. Liquid-cooled panels may be used, having one or more conduits or tubing therein, supplied with liquid through one conduit, with another conduit discharging warmed liquid, routing heat transferred from inside the melter to the liquid away from the melter. Liquid-cooled panels may also include a thin refractory liner, which minimizes heat losses from the melter, but allows formation of a thin frozen glass shell to form on the surfaces and prevent any refractory wear and associated glass contamination. Other useful cooled panels include air-cooled panels, comprising a conduit that has a first, small diameter section, and a large diameter section. Warmed air transverses the conduits such that the conduit having the larger diameter accommodates expansion of the air as it is warmed. Air-cooled panels are described more fully in U.S. Pat. No. 6,244,197, which is incorporated herein by reference. In certain embodiments, the refractory fluid cooled-panels are cooled by a heat transfer fluid selected from the group consisting of gaseous, liquid, or combinations of gaseous and liquid compositions that functions or is capable of being modified to function as a heat transfer fluid. Gaseous heat transfer fluids may be selected from air, including ambient air and treated air (for air treated to remove moisture), inert inorganic gases, such as nitrogen, argon, and helium, inert organic gases such as fluoro-, chloro- and chlorofluorocarbons, including perfluorinated versions, such as tetrafluoromethane, and hexafluoroethane, and tetrafluoroethylene, and the like, and mixtures of inert gases with small portions of non-inert gases, such as hydrogen. Heat transfer liquids may be selected from inert liquids which may be organic, inorganic, or some combination thereof, for example, salt solutions, glycol solutions, oils and the like. Other possible heat transfer fluids include steam (if cooler than the oxygen manifold temperature), carbon dioxide, or mixtures thereof with nitrogen. Heat transfer fluids may be compositions comprising both gas and liquid phases, such as the higher chlorofluorocarbons.
[0085] The feed slot described in accordance with the present disclosure may be constructed using refractory cooled panels. Both the feed slot and the side walls may include a thin refractory lining, as discussed herein. The thin refractory coating may be 1 centimeter, 2 centimeters, 3 centimeters or more in thickness, however, greater thickness may entail more expense without resultant greater benefit. The refractory lining may be one or multiple layers. Alternatively, melters described herein may be constructed using cast concretes such as disclosed in U.S. Pat. No. 4,323,718. The thin refractory linings discussed herein may comprise materials described in the 718 patent, which is incorporated herein by reference. Two cast concrete layers are described in the 718 patent, the first being a hydraulically setting insulating composition (for example, that known under the trade designation CASTABLE BLOC-MIX-G, a product of Fleischmann Company, Frankfurt/Main, Federal Republic of Germany). This composition may be poured in a form of a wall section of desired thickness, for example a layer 5 cm thick, or 10 cm, or greater. This material is allowed to set, followed by a second layer of a hydraulically setting refractory casting composition (such as that known under the trade designation RAPID BLOCK RG 158, a product of Fleischmann company, Frankfurt/Main, Federal Republic of Germany) may be applied thereonto. Other suitable materials for the refractory cooled panels, melter refractory liners, and refractory block burners (if used) are fused zirconia (ZrO 2 ), fused cast AZS (alumina-zirconia-silica), rebonded AZS, or fused cast alumina (Al 2 O 3 ). The choice of a particular material is dictated among other parameters by the melter geometry and type of glass to be produced.
[0086] Burners useful in the melter apparatus described herein include those described in U.S. Pat. Nos. 4,539,034; 3,170,781; 3,237,929; 3,260,587; 3,606,825; 3,627,504; 3,738,792; 3,764,287; and 7,273,583, all of which are incorporated herein by reference in their entirety. One useful burner, for example, is described in the 583 patent as comprising a method and apparatus providing heat energy to a bath of molten material and simultaneously creating a well-mixed molten material. The burner functions by firing a burning gaseous or liquid fuel-oxidant mixture into a volume of molten material. The burners described in the 583 patent provide a stable flame at the point of injection of the fuel-oxidant mixture into the melt to prevent the formation of frozen melt downstream as well as to prevent any resultant explosive combustion; constant, reliable, and rapid ignition of the fuel-oxidant mixture such that the mixture burns quickly inside the molten material and releases the heat of combustion into the melt; and completion of the combustion process in bubbles rising to the surface of the melt. In one embodiment, the burners described in the 583 patent comprises an inner fluid supply tube having a first fluid inlet end and a first fluid outlet end and an outer fluid supply tube having a second fluid inlet end and a second fluid outlet end coaxially disposed around the inner fluid supply tube and forming an annular space between the inner fluid supply tube and the outer fluid supply tube. A burner nozzle is connected to the first fluid outlet end of the inner fluid supply tube. The outer fluid supply tube is arranged such that the second fluid outlet end extends beyond the first fluid outlet end, creating, in effect, a combustion space or chamber bounded by the outlet to the burner nozzle and the extended portion of the outer fluid supply tube. The burner nozzle is sized with an outside diameter corresponding to the inside diameter of the outer fluid supply tube and forms a centralized opening in fluid communication with the inner fluid supply tube and at least one peripheral longitudinally oriented opening in fluid communication with the annular space between the inner and outer fluid supply tubes. In certain embodiments, a longitudinally adjustable rod is disposed within the inner fluid supply tube having one end proximate the first fluid outlet end. As the adjustable rod is moved within the inner fluid supply tube, the flow characteristics of fluid through the inner fluid supply tube are modified. A cylindrical flame stabilizer element is attached to the second fluid outlet end. The stable flame is achieved by supplying oxidant to the combustion chamber through one or more of the openings located on the periphery of the burner nozzle, supplying fuel through the centralized opening of the burner nozzle, and controlling the development of a self-controlled flow disturbance zone by freezing melt on the top of the cylindrical flame stabilizer element. The location of the injection point for the fuel-oxidant mixture below the surface of the melting material enhances mixing of the components being melted and increases homogeneity of the melt. Thermal NO x emissions are greatly reduced due to the lower flame temperatures resulting from the melt-quenched flame and further due to insulation of the high temperature flame from the atmosphere.
[0087] The term “fuel”, according to this disclosure, means a combustible composition comprising a major portion of, for example, methane, natural gas, liquefied natural gas, propane, atomized oil or the like (either in gaseous or liquid form). Fuels useful in the disclosure may comprise minor amounts of non-fuels therein, including oxidants, for purposes such as premixing the fuel with the oxidant, or atomizing liquid fuels.
[0088] The total quantities of fuel and oxidant used by the combustion system are such that the flow of oxygen may range from about 0.9 to about 1.2 of the theoretical stoichiometric flow of oxygen necessary to obtain the complete combustion of the fuel flow. Another expression of this statement is that the combustion ratio is between 0.9 and 1.2. In certain embodiments, the equivalent fuel content of the feed material must be taken into account. For example, organic binders in glass fiber mat scrap materials will increase the oxidant requirement above that required strictly for fuel being combusted. In consideration of these embodiments, the combustion ratio may be increased above 1.2, for example to 1.5, or to 2, or 2.5, or even higher, depending on the organic content of the feed materials.
[0089] The velocity of the fuel gas in the various burners depends on the burner geometry used, but generally is at least about 15 m/s. The upper limit of fuel velocity depends primarily on the desired mixing of the melt in the melter apparatus, melter geometry, and the geometry of the burner; if the fuel velocity is too low, the flame temperature may be too low, providing inadequate melting, which is not desired, and if the fuel flow is too high, flame might impinge on the melter floor, roof or wall, and/or heat will be wasted, which is also not desired.
[0090] In certain embodiments of the disclosure it may be desired to implement heat recovery. In embodiments of the disclosure employing a heat transfer fluid for heat recovery, it is possible for a hot intermediate heat transfer fluid to transfer heat to the oxidant or the fuel either indirectly by transferring heat through the walls of a heat exchanger, or a portion of the hot intermediate fluid could exchange heat directly by mixing with the oxidant or the fuel. In most cases, the heat transfer will be more economical and safer if the heat transfer is indirect, in other words by use of a heat exchanger where the intermediate fluid does not mix with the oxidant or the fuel, but it is important to note that both means of exchanging heat are contemplated. Furthermore, the intermediate fluid could be heated by the hot flue gases by either of the two mechanisms just mentioned.
[0091] In certain embodiments employing heat recovery, the primary means for transferring heat may comprise one or more heat exchangers selected from the group consisting of ceramic heat exchangers, known in the industry as ceramic recuperators, and metallic heat exchangers further referred to as metallic recuperators. Apparatus and methods in accordance with the present disclosure include those wherein the primary means for transferring heat are double shell radiation recuperators. Preheater means useful in apparatus and methods described herein may comprise heat exchangers selected from ceramic heat exchangers, metallic heat exchangers, regenerative means alternatively heated by the flow of hot intermediate fluid and cooled by the flow of oxidant or fuel that is heated thereby, and combinations thereof. In the case of regenerative means alternately heated by the flow of hot intermediate fluid and cooled by the flow of oxidant or fuel, there may be present two vessels containing an inert media, such as ceramic balls or pebbles. One vessel is used in a regeneration mode, wherein the ceramic balls, pebbles or other inert media are heated by hot intermediate fluid, while the other is used during an operational mode to contact the fuel or oxidant in order to transfer heat from the hot media to the fuel or oxidant, as the case might be. The flow to the vessels is then switched at an appropriate time.
[0092] Glass mat forming devices useful in the invention include slitting devices. These may be hot, cold, shear, or ultrasonic slitting devices, depending on the nature of the glass mat to be recycled. Slitting devices are commercially available, for example from AZCO Corp, Fairfield, N.J. (USA), under the trade designation ACU-SLIT™, and Automazioni Tessili Frigerio S.r.I., Via Giotto, 35-22075 Lurate Caccivio, Italy. AZCO Corp. also supplies a variety of roll handling equipment, such as unwinding equipment. Powered nip rolls are available from a variety of commercial sources, as are roll brakes. Roll handling equipment may comprise a roll chuck, a roll brake, and a safety chuck, useful with the roll stands 14 and unwind devices 15 illustrated in FIGS. 1 and 2 . Suitable roll chucks include air-inflated bladder chucks having an air-inflated bladder (not illustrated) which engages an inside surface of a roll core when inflated. Such chucks are available from several commercial sources, including, for example, Double E Company, LLC, West Bridgewater, Mass. (USA). A suitable roll brake includes a series of heat transfer cooling fins illustrated inside a safety cage. Roll brakes are also available from many sources, including the Double E Company. A hand-held air nozzle and compressed air hose may be available locally at roll stands 14 . Compressed air nozzles and hoses are useful for the operator for many reasons, including topping off the air in the air-inflated bladder chucks, if deemed necessary by the operator, blowing off accumulated dust from equipment and clothes, and the like. Safety chucks are known in the roll handling art and usually include a mechanism to safely immobilize the roll. Safety chucks are available in a variety of designs, and are available from many sources, including the aforementioned Double E Company.
[0093] Roll stand 14 may include a roll alignment sensor, sometimes referred to as an edge guide, which may include a servo cable allowing communication between the sensor and a roll stand controller (not illustrated) to maintain roll of glass mat material 16 unwinding with proper alignment.
[0094] Apparatus of this disclosure may further optionally comprise one or more idler rolls and one or more anti-static devices useful with roll stand 14 illustrated in FIGS. 1 and 2 . One anti-static device may comprise a rigid delivery tube positioned near the glass mat web as it unwinds, which is connected to a flexible delivery tube which supplies ionized air or other ionized gas to the rigid tube. Ionized air or other ionized gas exits the rigid tube through a plurality of holes or through a ceramic frit material and onto the glass mat material to remove static electricity. Without static electricity reduction, subsequent forming steps and other movements could be difficult. In addition, static shocks to workers can be painful and otherwise disruptive ergonomically.
[0095] Powered nip rolls 24 ( FIGS. 1 and 2 ) and alternatives mentioned herein may be controlled by a controller 300 as previously discussed. Nip rolls may be part of a nip roll assembly, comprised of one or more idler rolls. Nip roll pairs may be designed to move up and down when desired by the operator, upon command from a main controller, usually by compressed air-actuated cylinders. Nip rollers in nip roller pairs 24 are typically rubber or rubber-covered rolls, available from many commercial sources.
[0096] Although only a few exemplary embodiments of this disclosure have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel apparatus and processes described herein. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, no clauses are intended to be in the means-plus-function format allowed by 35 U.S.C. §112, paragraph 6 unless “means for” is explicitly recited together with an associated function. “Means for” clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. | 4y
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[0001] This is a continuation of application Ser. No. 10/416,190, filed on May 9, 2003; as a National Phase Application of International Application Number PCT/US01/43034, filed on 9 Nov. 2001, claiming priority of U.S. Provisional Application 60/246,756, filed on Nov. 9, 2000; now U.S. Pat. No. 7,217,056, granted on May 15, 2007.
BACKGROUND OF THE INVENTION
[0002] Many conventional drilling rigs use a top-drive for pulling pipe and/or tools from a well bore. Powerful motors are used to pull and wind wire rope, cable or strand about a drum located above the derrick floor. Swivels are used in-line with helical wound members such as rope, cable or strand for allowing rotation about a longitudinal axis thereof under tension for minimizing or avoiding straightening of the helical windings in order to protect the strength and integrity of the rope, cable or strand by compensating for the torsional force induced by large axial forces on the helical member. Typical forces can be on the order of several tons, or more.
[0003] In one typical operation referred to as a “wireline strip over operation”, a sinker bar is used in-line with the wire rope. Sinker bars have in the past been comprised of a rigid member which may be in the form of a solid bar on the order of 15 to 20 feet in length. Use of such a sinker bar with a top drive creates interference between the sinker bar and rig equipment located vertically above the drill pipe; heretofore, it has been necessary to move and relocate the top drive unit out of the way. This is a time consuming operation that is best to be avoided.
SUMMARY OF THE INVENTION
[0004] The invention relates to the use of a unique implement which is now referred to as a “knuckle=swivel” and which provides for the multiple function of introducing a 360 degree swivel capability for minimizing and/or precluding the above referred torsional forces on the rope, cable or strand and, in addition, provides for a knuckle function to allow angular displacement for minimizing or precluding bending loads transmitted into the swivel during withdrawal of sinker bars from the well bore or other tools and the like being pulled around an obstacle.
[0005] The present invention is particularly useful for well drilling operations including but not limited to those utilizing a top drive winding drum for pulling items from the well bore and, more particularly, the invention is intended to be used with “Flexible Sinker Bar Assemblies” which are the subject of my U.S. Pat. No. 6,227,292 B1, granted on May 8, 2001; the disclosure of my earlier patent is incorporated herein by reference. An important feature of the present invention resides in the combination of the instant knuckle-swivel and a sinker bar, either a rigid sinker bar or ideally a flexible sinker bar, in order to minimize or preclude the heretofore requirement of moving the top drive unit during pulling operations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a longitudinal, sectional view of a knuckle-swivel in accordance with the invention.
[0007] FIG. 2 is a side elevational view of the knuckle-swivel showing the extent of side rotation.
[0008] FIG. 3 is a schematic representation of the knuckle-swivel connected to a helical wound wire rope, cable or strand which comprises part of a sinker bar.
[0009] FIG. 4 is a schematic view showing a helical wound rope, cable or strand being, diverted around rig equipment with the knuckle-swivel located at the mouth of the well.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] A knuckle-swivel body member, generally indicated by the numeral 10 , includes a bottom sub 14 having threads 16 at one end thereof and receiving a bearing pin 18 in its opposite hollow end 20 and being connected thereto by a slotted spring pin 22 .
[0011] An upper sub 24 includes a first threaded end 26 and a second threaded end 28 , the latter being connected to the knuckle-swivel body member 10 in alignment with bottom sub 14 . Body member 10 contains a pair of bearing cones 30 , 30 , a pair of bearings cups 32 , 32 and a pair of bearing races 34 , 34 which are mounted upon cylindrical posts 36 , 36 disposed on opposite sides of bearing pin 18 . A flat wire compression spring 40 , of a type known as a crest-to-crest spring, is located between one bearing cup 32 and the adjacent end of upper sub 24 for applying a constant force against the cup 32 for stabilizing a plurality of ball bearings 42 between the bearing cones 30 , 30 and the bearing races 34 , 34 . A grease fitting 44 is provided for passing lubricant through a passage 46 , it being understood that the lubricant can pass through spring 40 and protect the various bearing components.
[0012] As is best shown in FIG. 1 , body member 12 is provided with a frusto-conical surface 50 which limits bearing pin 20 to approximately 20 degrees of side-to-side rotation, the extent of rotation being best shown in FIG. 2 . Thus, bearing pin 18 is capable of rotating 360 degrees about its longitudinal axis within body member 12 in addition to a side-to-side conical movement of 20 degrees.
[0013] Referring to FIGS. 3 and 4 , it will be seen that the knuckle-swivel 10 is secured by a swaged end connector 60 to a line 62 , which may be a helical wound wire rope, or cable, or strand member. It is to be understood that helical wound line 62 is protected by knuckle-swivel 10 because of the capability of 360 degrees of axial rotation of bearing pin 18 minimizes or precludes torsional forces upon the line 62 . In the absence of such protection, large axial loads would tend to straighten the helical windings and thereby severely weaken the strength of the line 62 . End connector 60 is threaded onto sub 14 , and sub 24 can be threadedly connected to a pipe or tool 64 .
[0014] It is to be understood that it is conventional in the well drilling industry to provide a top drive (not shown) in the form of a winding drum located at or near the top of a derrick or rig, for pulling pipe or tools from the well. It is not unusual for portions of the derrick or rig to be interposed between the well head and the winding drum. As a result, it has heretofore been necessary to mount the top drive so that it may be adjustably moved laterally to prevent interference between the pulling line and rig. As is best shown in FIG. 4 , line 62 , which may be a component of a flexible sinker bar as described in U.S. Pat. No. 6,227,292, can be angularly displaced while under load because of the provision of knuckle-swivel 10 . As a result, interference with rig equipment, generally indicated by the numeral 80 , is avoided and it is unnecessary to move or relocate the top drive member. Line 62 can be trained over a guide roller (not shown) upwardly of or adjacent the rig equipment 80 for preventing contact during a wireline strip over operation, or the like.
[0015] From the foregoing, the preferred construction of the invention will be obvious to those skilled in this art but it is to be understood that some changes in construction and operation are possible without departing from the spirit and scope of the invention as defined in the claimed subject matter appended hereto. | 4y
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